5040140 EVINRUDE Fuel Filter Assembly Exhaust & Evaporative emissions related part

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Note: If the problem only occurs under certain conditions, test the engine under those conditions. Examples of certain conditions are high engine idle, full load, or a specific operating temperature. Troubleshooting the symptoms under other conditions may give misleading results.Diagnostic Codes and Event Codes
Certain diagnostic codes and/or event codes may cause poor performance. Connect the Caterpillar Electronic Technician (ET) and check for active codes and/or logged codes. Troubleshoot any codes that are present before continuing with this procedure.Note: Although a sensor's signal may be in the operational range of the sensor, certain failure modes of a sensor may produce an output signal that does not represent an accurate measurement. Use Cat ET to check that the pressures and the temperatures are fluctuating normally. Also check that the values are reasonable for the conditions that are present.Starting Aids
Verify the correct operation of the starting aid. Refer to Troubleshooting, "Ether Starting Aid - Test".Engine Speed/Timing Sensor
Check the speed/timing circuit. Refer to Troubleshooting, "Speed/Timing - Test".Low Pressure Fuel System
Visually check the fuel level in the fuel tank. Do not rely on the fuel gauge only. If necessary, add fuel to the fuel tank. If the engine has been run out of fuel, it will be necessary to prime the fuel system. Refer to Systems Operation/Testing and Adjusting, "Fuel System - Prime".
Cold weather adversely affects the characteristics of the fuel. Refer to the Operation and Maintenance Manual for information on improving the characteristics of the fuel during cold weather operation.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Do not loosen any high pressure fuel lines when the engine is running. The high pressure in the fuel lines can cause personal injury or death. Wait 60 seconds after the engine has stopped to allow pressure to purge before any service or repair is performed on the engine fuel lines.
Check the fuel lines for the following problems: restrictions, collapsed lines and pinched lines. If problems are found with the fuel lines replace the lines.
Check the fuel tank for debris or foreign objects which may block the fuel supply.
Check the fuel pressure during engine cranking. Check the filtered fuel pressure. Refer to Systems Operation/Testing and Adjusting, "Fuel System Pressure - Test".
Check the fuel quality. Refer to Systems Operation/Testing and Adjusting, "Fuel Quality - Test". High Pressure Fuel System
Inspect the high pressure fuel system. Check the following components:
High pressure fuel pump
Fuel rail
Fuel lines
Illustration 1 g01735374
Harness connectors for the high pressure fuel pump
(1) Harness connector for side 1
(2) Harness connector for side 2
Disconnect each harness connector from the pump. Look for fuel on the connectors. If there is fuel in the connectors, clean the connectors. Having clean connectors will help ensure a good connection.
Use Cat ET in order to monitor the "Fuel Rail Pressure (absolute)" status parameter while you crank the engine. Note: The engine cranking speed must be at least 150 RPM.
If the fuel rail pressure is less than 10 MPa (1450 psi), refer to Systems Operation/Testing and Adjusting, "High Pressure Fuel Bypass - Test". Intake Manifold Pressure Sensor
Monitor the status of "Fuel Position", "Rated Fuel Limit", and "FRC Fuel Limit" on Cat ET while the engine is operating under full load. These parameters should agree with the information below.
Table 1
"Fuel Position" = "Rated Fuel Limit"
and
"Fuel Position" < "FRC Fuel Limit" If "Fuel Position" equals "Rated Fuel Limit" and "Fuel Position" is less than "FRC Fuel Limit", the electronics are operating correctly. Otherwise, proceed with the next step.
Monitor the status of "Intake Manifold (Boost) Pressure" and "Atmospheric Pressure" for normal operation on Cat ET. When the engine is not running, "Intake Manifold (Boost) Pressure" should be 0 kPa (0 psi). Air Inlet and Exhaust System
Check the air filter restriction indicator for a plugged filter. If necessary, service the engine. Refer to the Operation and Maintenance Manual.
Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Systems Operation/Testing and Adjusting.