0397207 EVINRUDE CYLINDER C'CASE ASSY., 90 only

Table 1
Diagnostic Trouble Codes    
CDL Code    J1939 Code    Code Description
(code descriptions may vary)    Comments    
E096 (2)     5580-16     High Fuel Pressure     The code is logged.
The fuel pressure is above the trip point pressure.    
Table 2
Troubleshooting Test Steps    Values    Results    
1. Determine the Code
A. Connect Cat ET to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Determine if a diagnostic trouble code is present.
   
Diagnostic trouble code
   
Result: A E096 (2) or 5580-16 code is present.
Proceed to Test Step 2.
Result: A code other than E096 (2) or 5580-16 code is present.
Troubleshoot the code. Refer to the proper troubleshooting procedure.
   
Table 3
Required Tooling    
8t-7860 Connector    
110-6349 Fitting as    
8t-0855 Pressure Gauge    
6v-3990 Coupler    
Illustration 1 g02023390
(1) Fuel temperature sensor (2) Fuel sampling port (3) Fuel pressure sensor (4) Secondary fuel filter baseDo not use the fuel sampling port (2) for measuring the pressure. Follow the steps below.
Table 4
Troubleshooting Test Steps    Values    Results    
2. Check the Fuel Pressure Sensor
A. Record the fuel pressure from Cat ET. Record the data in Table 5.
B. Remove the fuel pressure sensor (3) .
C. Install an 8T-7860 Connector into the port of the pressure sensor (3).
D. Install the 110-6349 Fitting as onto the 8T-7860 Connector .
E. Install a 8T-0855 Pressure Gauge onto a 6V-3990 Coupler .
F. Install the 6V-3990 Coupler onto the 110-6349 Fitting as.
After the pressure sensor is removed, a code for low fuel pressure will become active. Reset all active codes and clear all logged codes by cycling the keyswitch to the Off position, after the sensor is reinstalled.
G. Record the fuel pressure on the pressure gauge. Record the data in Table 5.    
Fuel pressure
   
Result: The gauge value of the fuel pressure is within
137 kPa (20 psi) of the fuel pressure reading shown in ET.
Proceed to Test Step 3.
Result: The gauge value of the fuel pressure is not within
137 kPa (20 psi) of the fuel pressure reading shown in ET.
Replace the pressure sensor. Reset all active codes and clear all logged codes by cycling the keyswitch to the Off position. Verify that the problem has been resolved.
If the problem is not resolved, proceed to Test Step 3.
   
Table 5
Engine RPM     Fuel pressure from Cat ET     Fuel pressure from the mechanical gauge    
800            
1800            
Illustration 2 g02023433
Fuel supply lines
Illustration 3 g02024502
Return fuel line
Table 6
Troubleshooting Test Steps    Values    Results    
3. Inspect the Fuel Supply Lines
A. Visually inspect the fuel lines between the primary filter base and the inlet to the cylinder head. Also, inspect the fuel cooler, if equipped. Inspect the fuel return line from the head to the fuel tank. Inspect the lines for restrictions, pinching, and swelling.
   
Restrictions, pinching, and swelling
   
Result: The fuel lines and the cooler (if equipped) are OK.
Proceed to Test Step 4.
Result: The fuel lines and the cooler (if equipped) are not OK.
Make the necessary repairs. Reset all active codes and clear all logged codes by cycling the keyswitch to the Off position. Verify that the problem has been resolved.
If the problem is not resolved, proceed to Test Step 4.
   
Illustration 4 g02024508
(5) Return fuel pressure regulator
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