5004912 EVINRUDE *GEARCASE & BEARING Assy

Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.There have been instances of visible white smoke when the engine is at low idle or high idle. This issue can occur when the engine is cold or when the engine is at normal operating temperature.Do not confuse this issue with other exhaust smoke conditions. Refer to Special Instruction, M0079308, Smoke Identification and Troubleshooting on Certain C7.1 Mechanical Engines for further guidance.Safety Section
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Procedure
Do not perform any other repair for this issue other than the solution that is identified below. Other repairs may damage the engine. Other repairs may also cause the engine not to be compliant with emissions regulations.
When the white smoke issue has been identified, perform the following procedure:
Ensure that the engine is in a cold condition.
Take a video of the exhaust emissions during the following steps:
Start the engine and hold at low idle for 20 seconds.
Stop the engine.
Ensure that "Auto Engine Control" is disabled.
Start the engine. Turn the "Engine Speed Control" from position "1" to position "10". Hold at high idle for 20 seconds.
Operate the engine until the following conditions are met:
Coolant temperature is greater than 85° C (185° F)
Hydraulic oil temperature is greater than 55° C (131° F)
Take a video of the exhaust emissions during the following steps:
Start the engine and hold at low idle for 20 seconds.
Ensure that "Auto Engine Control" is disabled.
Stop the engine.
Start the engine. Turn the "Engine Speed Control" from position "1" to position "10". Hold at high idle for 20 seconds.
If there have been repeat occurrences of this issue, collect a 2 L (0.5 US gal) fuel sample from the fuel tank. Retain the fuel sample and await instruction on how to process the sample.
Check that the coolant temperature switch is operating correctly. If necessary, install a new coolant temperature switch.Perform the following steps to install a new coolant temperature switch:
Illustration 1 g06232958
Typical example
Drain the engine coolant. Refer to Operation and Maintenance Manual, Cooling System Coolant (ELC) - Change.
Disconnect Cable (2) from Switch (1).
Remove Switch (1) from the cylinder head.
Install Switch (1) in the cylinder head. Tighten the Switch to a torque of 16 N m (142 lb in).
Connect Cable (2) to Switch (1).
Refill the engine coolant. Refer to Operation and Maintenance Manual, Cooling System Coolant (ELC) - Change.
If the fault is still present, proceed to Step 7.
If the smoke condition is continuous at low idle or high idle, check the low-pressure fuel system. Check the Electric Fuel Lift Pump (EFLP), the fuel filters and the fuel lines for blockages or air in the fuel. Refer to Systems Operation, Testing and Adjusting, Fuel System for more information.
Perform any necessary repairs on the low-pressure fuel system.
Check the engine valve lash and if necessary, adjust the valve lash. Refer to Systems Operation, Testing and Adjusting, Engine Valve Lash - Inspect/Adjust.If the fault is still present, proceed to Step 10.
Check the fuel injection nozzles. Refer to Systems Operation, Testing and Adjusting, Fuel Injection Nozzle - Test.
Replace any suspect fuel injectors. Refer to Disassembly and Assembly, Fuel Injector - Remove and Disassembly and Assembly, Fuel Injector - Install.
If the fault is still present, install a replacement 449-3641 Fuel Injection Pump. Refer to Disassembly and Assembly, Fuel Injection Pump - Remove and Disassembly and Assembly, Fuel Injection Pump - Install for the correct procedure.Note: Ensure that the removed fuel injection pump is locked in the correct position.Plug all connections on the removed fuel injection pump.Take photographs of the ID plates on the removed pump and the new pump.Retain the removed fuel pump for 30 days. The fuel pump may be requested for return through the Send It Back (SIB) process. Ensure that the fuel injection pump is well packaged and protected from damage before shipping.Submit a Dealer Solution Network (DSN) ticket with the following information:
Videos of exhaust emissions
Machine Serial Number
Machine running hours
Photographs of the fuel injection pump ID plates
Special Instruction Media number M0088717
CPI number 390829