Service Manual 5008736_55 MFE Fuel System [Fuel Component Servicing]

Gasoline is extremely flammable and highly explosive under certain conditions. Use caution when working on any part of the fuel system.
Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure. Refer to Relieving Fuel System Pressure.
Always work in a well ventilated area and wipe off any fuel spillage.
DO NOT smoke and make certain no open flames or ignition sources exist.
After servicing the fuel system check for leaks. Failure to check for fuel leakage could allow a leak to go undetected, resulting in fire or explosion.

Relieving Fuel System Pressure

IMPORTANT: Minimize fuel system pressure before disassembly. Temporarily restrict the fuel supply hose from fuel tank with hose pincer . Remove propeller (MRL) and disconnect circulation fuel pump electrical connector. If outboard runs, start an d run at IDLE for 5 seconds and STOP outboard. If outboard does NOT run, crank for 10 seconds.

Wrap a shop towel completely a round the pressure test valve while connecting fitting from Fu el Pressure Gauge, P/N 5007 100, to top test fitting of fuel pump/vapor separator assembly

005011

1. Shop towel

Insert venting hose of ga uge into a suit able container.

Slowly open gauge’s venting valve.

Clean up any spilled fuel with shop towels.

005012

1. Test fitting
2. Venting valve
3. Venting hose

Removal

Remove filter carefully to prevent spilling contents.

Inspect contents for any presence of water. If water is p resent, identify the source and correct the problem. Take additional fuel samples and drain fuel tank(s) if necessary.

002192

1. Fuel filter
2. Arrow

Installation

Install filter in fuel supply hoses. Note arrow indicating direction of fuel flow on filter . Secure filter with appropriate clamps. Refer to Oetiker Clamp Servicing on p. 28.

Squeeze primer bulb to prime fuel system. Hold pressure on bulb and check for fuel leaks.

Run outboard and check for fuel leaks.

The fuel lift pump is service able as a complete assembly or can be repaired with a fuel pump repair kit. Refer to parts catalog for service parts.

Removal

Disconnect the fuel hoses from the fuel pump housing. Label hoses for reassembly locations. Disconnect the fuel lift pump pulse hose at the crankcase fitting.

006558

1. Crankcase fitting

Loosen the fuel lift pump mounting screws. Remove the fuel lift pump as an assembly.

002194

1. Screws

Fuel pump repair kit, P/N 438616, is available for internal service of fuel pump. Refer to instructions included with kit.

Installation

Place fuel pump in position on crankcase. Apply Nut Lock to mounting screws. Tighten screws to a torque of 24 to 36 in. lbs. (2.8 to 4.0 N·m).

Connect the fuel lift pump pulse hose to the crankcase. Secure with tie strap.

Connect the fuel hoses to the fuel filter. Secure with Oetiker clamps.

Squeeze primer bulb to prime fuel system. Hold pressure on bulb and check for fuel leaks.

Run outboard and check for fuel leaks.

Removal

Relieve fuel system pressure. Refer to Relieving
Fuel System Pressure on p. 144.

Disconnect circulation pump electrical connector.

Remove clamp and fuel supply manifold from top of circulation pump. Remove clamp and vapor vent hose from separator cover.

Remove clamp s and vapor separator cooling water hoses.

Remove clamps and fuel return manifold and fuel supply hose from bottom of vapor separator.

Remove the vapor separator housing retainer clip.

005013

1. Retainer clip

Remove vapor separator/fuel pump from the mounting stud and slide vapor separator housing from the grooves of the isolator mounts.

Installation

Slide the vapor separator bracket notches in to grooves of the isolator mounts. Install forward isolator of vapor separator on mounting stud and secure with retainer clip.

007859

1. Notches
2. Isolator mounts

Install all hoses and manifolds in original locations and secure with appropriate clamp s. Refer to Oetiker Clamp Servicing on p. 28. Route hoses and secure with tie straps as shown.

007860

Squeeze primer bulb to prime fuel system. Hold pressure on bulb and observe for fuel leaks.

Run outboard and check for fuel leaks.

Removal

Relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 144.

Remove oil tank assembly. Refer to Oil Tank Assembly on p. 166.

Remove clamps and disconnect the fuel manifolds as follows:

• Fuel supply manifold to circulation pump.
• Fuel return manifold to vapor separator.

006555

1. Fuel supply manifold
2. Fuel return manifold

Remove fuel manifold retainer screws and remove retainers from fuel injectors.

006559

1. Screw

Disconnect fuel manifold fittings from fuel injector ports, then remove the manifold assemblies.

Installation

Check condition of sealing O-rings on fuel manifold fittings. Lubricate O-rings with outboard lubricant and insert fuel manifold fittings into injector.
Both fittings must be fully seated into the injector
fuel ports.

Install retainer in the outer groove of the manifold fittings. Install and tighten screw to a torque of 24 to 36 in. lbs. (2.7 to 4 N·m).

005342

1. Retainer
2. Manifold fitting groove

Install the fuel manifolds to the fuel pump assembly and secure with clamps:

• Fuel supply manifold to circulation pump.
• Fuel return manifold to vapor separator.

Install oil tank assembly. Refer to Oil Tank Assembly on p. 166.

Mark fuel injector(s) to show cylinder location(s).

Fuel injectors must be installed in the correct cylinder locations. Use Evinrude Diagnostics Software to make sure that EMM programming matches injector positioning. The Injector Coefficients screen displays injector serial numbers for each cylinder.

008568
Injector Coefficients Screen

Use caution when handling fuel injectors. Prevent dirt and debris from entering fuel inlet and outlet ports of injectors or fuel manifolds. Cover the injector nozzle port in cylinder head to prevent contamination of combustion chamber.

Removal

Relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 144.

Remove fuel manifold s. Refer to Fuel Manifold Service on p. 147.

Remove the ignition coil assemblies.

Disconnect the fuel injector electrical connector.

Remove injector screws.

006561

1. Injector screws

Remove fuel injector and insulator.

Crush Ring Replacement

Injector crush rings must be replaced if injector is installed in a different head or cylinder location.

Use Slide Hammer assembly, P/N 39100 8, with Slide Hammer Adaptor kit, P/N 390898, to remove injector from mounting cup.

Thread adaptor and stud into face of injector. Hold mounting cup securely. Use slide hammer to separate injector from mount housing.

002345

Remove adaptor from injector. Remove crush ring and O-rings from injector. Inspect and clean injector filter as required. Install new crush ring and Orings. Lubricate O-rings with STP† Oil Treatment.

002196

1. Adaptor

002317

1. Crush ring
2. O-rings

Install injector into mount housing. Press on injector face until injector seats in mount housing.

002318

Installation

All injectors must be installed in the correct cylinder by serial number. Improper injector installation can result in powerhead failure.

Installation of a replacement injector requires that coefficient data for the new injector is uploaded to the EMM.

Coefficient data for some replacement injectors is supplied on a computer disk shipped with the injector. If a disk is not included with the injector, coefficient dat a ca n be downloaded from the Evinrude/Johnson dealer website. Refer to the instructions provided with the injector kit.

Upload Coefficient Files to EMM

Use t he Evinrude Diagnostics software Settings screen to upload the coefficient file to the EMM.

Select the Injectors tab.

Select the cylinder tab for injector being replaced.

Select the Replace Injector button.

008568A

1. “Replace Injector” button

Use the drop down menu to navigate to the saved coefficient file location.

The coefficient file name must match the serial number of the injector.

Select the correct file for the injector.

Select the Replace Injector button.

008573

1. Navigation menu
2. Injector coefficient file
3. “Replace Injector” button

After the upload is complete, t he program will return to the Cylinder tab.

Make sure the serial number displayed o n the screen matches the serial number printed on the serial number label of the replacement injector.

008568A

1. Serial number

Install Injector

The following items and their ma ting surfaces must be cleaned prior to reassembly:

• Injector
• Cylinder head
• Adapter
• Screws
• Threaded areas

All injector components must be clean to ensure correct torque tightening specifications. To prevent fuel leakage, carefully follow these installation instructions.

Place injector and insulator in the proper cylinder location.

IMPORTANT: Be careful not to pinch any wiring or hoses during assembly.

Lubricate mounting screw threads and under the head of the screw with a light coat of Triple-Guard grease. Install washers (on e per screw) on injector retaining screws. In stall screws and washers through mounting flange of injector and into cylinder head.

002316

Tighten screws in stages, starting with the lower screw.

• First torque is 5 ft. lbs. (7 N·m).
• Second torque is 10 ft. lbs. (14 N·m).
• Final torque is 24 to 26 ft. lbs. (33 to 35 N·m).

006562
Tighten Screws in Stages

Reconnect fuel injector electrical connectors.

Install the ignition coil assemblies. Tighten coil screws to a torque of 60 to 8 4 in. lbs (7 to 9.5 N·m).

Install fuel manifolds. Refer to Fuel Manifold Service on p. 147.

Removal

Disconnect vapor separator vent hose, main bearing vent hose, air temperature sensor, crankshaft position sensor, and throttle position sensor.

Use Ball Socket Remover Tool, P/N 342226, to remove throttle link arm.

Remove throttle body screws a nd throttle body assembly.

002499

1. Link arm
2. Throttle body screws

Remove gasket from throttle body.

Remove screws and reed plate assembly from the crankcase.

002503

1. Screws

Disassembly

All reed plate assembly an d reed valve assemblies must be cleaned prior to reassembly. DO NOT use strong carburetor cleaner or the hot soaking tank method for cleaning.

Remove the reed valve retainer screws a nd remove the assembly.

002496

Use caution to prevent damaging reed valve assemblies.

002504

DO NOT disassemble reed valve assemblies. Damaged reed plates are not serviceable and are replaced as an assembly.

Inspection

Inspect the leaf plate assemblies for da mage or contamination:

• Leaf plates must not be distorted.

• Leaf valve must not be cracked or chipped.

• Leaf plate stops must not be distorted or loose.

• Leaf plate assemblies must be clean.

Inspect t he intake manifold. All gasket surfaces must be cleaned, smooth, and free of nicks. Use a machinist’s straight-edge and a feeler gauge to check flatness in all directions. Surface must be flat, ±0.004 in. (0.10 mm).

002324

1. Straight-edge

Assembly

Remove old adhesive from reed valve retaining screws.

Install gasket on reed plate assembly . DO NOT use sealer on the gasket.

002333

Prime screw threads with Locquic Primer and let dry. Apply Nut Lock to threads. Position reed valve on reed plate an d install screws. Tighten screws to a torque of 25 to 35 in. lbs. (2.8 to 4.0 N·m).

002326

Installation

Place reed plate assembly on cylinder/crankcase. Apply Nut Lock to two reed plate screws. Inst all and tighten screws to a torque of 60 to 120 in. lbs. (7 to 13.5 N·m).

002505

Place gasket on throttle body. Install throttle body on reed plate and install new screws.

IMPORTANT: If old screws must be re-used, make sure all previous thread locking material is removed and apply Nut Lock to threads.

Tighten the center screws first and expand outward. Tighten in stages to a final torque of 60 to
120 in. lbs. (7 to 13.5 N·m).

002501

Install vapor separator vent hose and main bearing vent hose. Secure with tie straps.

Install air temperature sensor, crankshaft position sensor, and throttle position sensor electrical connectors.

Connect throttle linkage.

IMPORTANT: DO NOT lubricate th rottle linkages.

002500

1. Throttle linkage
2. Clamp

Refer to TPS Calibration on p. 126.