5005969 Service Manual - French EVINRUDE
E40DELSOR, E40DPLSOR, E40DRLSOR, E50DPLSOR, E60WDRLSOS
Service
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BRP EVINRUDE entire parts catalog list:
- LITERATURE » 5005969
E40DRLSOR 2004,2005
E50DPLSOR 2004,2005
E60WDRLSOS, E60WDRYSOS 2004,2005
Information:
Recommended Actions
Note: If the symptom only occurs under certain operating conditions (high idle, full load, engine operating temperature, and so on), test the engine under the conditions. Troubleshooting the symptom under other conditions can give misleading results.Cold Cylinder
Use the exhaust temperature scanner to view the temperatures of each individual cylinder. Compare the temperature readings in order to identify a cold or misfiring cylinder. Refer to Systems Operation/Testing and Adjusting, KENR5473, "Exhaust Temperature Module" for information related to use of the exhaust temperature scanner.If there is an indication of a misfiring cylinder, check the following components for problems:
Spark plugs
Extenders
Ignition transformers
Primary wiring for the ignitionInspect each of the extenders for signs of pin holes and/or of electrical arcing.Refer to Troubleshooting, "Ignition Secondary - Test".Electrical Connectors or Power Supply
There may be an intermittent interruption of power that is causing the symptom. Check the wiring harnesses and the connectors. Inspect the connectors in each of the junction boxes. Inspect the power supply connections and the ground connections.Inspect the wiring from the power supply to the Electronic Control Modules (ECM). Refer to Troubleshooting, "Electrical Power Supply - Test" for information that is related to the wiring harnesses and connectors.Ignition System
Inspect the ignition transformers for the following conditions: loose connections, moisture, short circuits and open circuits. Inspect the primary wiring and the secondary electrical connections.Ensure that the correct transformers and spark plugs are installed on the engine. Inspect the extenders for signs of pin holes and of electrical arcing. Check the spark plugs for fouling, correct gap adjustment, and moisture.Maintain the spark plug according to the engine Operation and Maintenance Manual.Incorrect Base Timing
Verify that the base timing is correct. Refer to Systems Operation/Testing and Adjusting, "Ignition Timing - Adjust".Fuel Supply
Use Cat ET to check that the engine fuel parameters are correct for the fuel that is being used. If necessary, perform fuel analysis in order to confirm the fuel quality.Verify that the fuel pressure is correct. When possible, interview the operator in order to determine if fuel quality is in question. Try to determine if the source of the fuel has been changed.Ensure that fuel is supplied at a sufficient pressure that is stable. Check that the size of the fuel line is sufficient. Inspect the fuel system for leaks.The following conditions can affect engine starting:
Low fuel pressure
High fuel pressure
Poor fuel qualityInspect the following fuel system components:
Fuel filter
Gas pressure regulator
Gas shutoff valve
Fuel metering valveVerify that the system components are operating correctly.Repair suspect components. Replace the fuel filter, if necessary.Inspect the fuel system for debris or moisture buildup. Repair and/or replace as necessary.Incorrect Air/Fuel Ratio
An air/fuel mixture that is too rich or too lean will have an adverse effect on engine operation. Verify that the exhaust emissions are correct. Refer to Troubleshooting, "Nitrogen Oxide Sensor - Calibrate".Be sure to use an accurate instrument for your measurements. Use of instrumentation that is not properly calibrated can lead to an improper diagnosis of the problem.A change in the fuel energy content will change the air/fuel ratio. Obtain a fuel analysis.If the fuel analysis is as expected, inspect the NOX sensor port in the flower pot for plugging. If necessary, clean the port. If the problem persists, refer to Troubleshooting, "Detonation Occurrence".The fuel supply pressure must be 876 to 1289 mbar absolute or 12.705 to 18.695 PSI. The gas differential pressure (delta-p) should be between 69 and 345 mbar. Delta-p below this range is allowed during cranking and idle conditions, but accuracy of the valve will be reduced. For delta-p above 276 mbar, flow accuracy will also decrease, and a reduction in valve stability may occur. Minimum proof pressure for the fuel metering valve is 0.52 bar gauge. Minimum burst pressure for the fuel metering valve is 1.72 bar gauge.Incorrect Governor Adjustment
The governor parameters must be programmed with the values that provide stable operation. Refer to Systems Operation/Testing and Adjusting, "Engine Governing - Adjust".Compressor Bypass Valve
The compressor bypass valve and the compressor bypass actuator must be installed properly in order to provide stable operation. Inspect the mechanical condition of the components. Refer to the Disassembly and Assembly for information that is related to the correct installation of the compressor bypass valve and the compressor bypass actuator.Exhaust Bypass Valve
An improperly adjusted exhaust bypass valve can affect engine performance. If the engine has experienced a change in the operating load, the operating altitude, or the ambient temperature check the setting of the exhaust bypass valve. Refer to Systems Operation/Testing and Adjusting, "Exhaust Bypass Valve - Adjust" for details.Air Inlet Restriction
The maximum allowable air inlet restriction is 3.75 kPa (15 inches of H2O). If the air inlet restriction is higher than the specification, clean the filter element or install a new filter element. Check the restriction again. If the restriction remains too high, inspect the air inlet piping for obstructions.For more information, refer to Systems Operation/Testing and Adjusting, "Restriction of Air Inlet and Exhaust". Also, refer to Installation Guide, LEBW5339, "G3500 GAS ENGINES APPLICATION & INSTALLATION GUIDE".Exhaust Restriction
Measure the exhaust restriction during engine operation with a load. For data that is specific to your engine, refer to Installation Guide, LEBW5339, "G3500 GAS ENGINES APPLICATION & INSTALLATION GUIDE". Also, refer to the engine performance data sheet.Investigate the cause of the exhaust restriction. Perform adjustments and/or repairs, as needed.Throttle Valve Differential Pressure Sensor
Verify that the throttle valve differential pressure sensor is producing the correct signal. Use a 1U-5470 Engine Pressure Gp to measure the throttle valve differential pressure. Compare the reading with the value that is displayed on Cat ET. Replace the sensor, if necessary.Throttle Actuator
Set the engine control to the OFF/RESET position. Remove the electrical power from the engine. Move the throttle plate through the entire range of travel while you feel the motion. If the motion is sticky and/or rough, investigate the cause of the binding. Perform the necessary repairs.Incorrect Valve Lash
Check the valve lash. Refer to Systems Operation/Testing and Adjusting, "Valve Lash and Valve Bridge Adjustment" for information that is related to adjusting the valve lash for the engine.Cylinder
Note: If the symptom only occurs under certain operating conditions (high idle, full load, engine operating temperature, and so on), test the engine under the conditions. Troubleshooting the symptom under other conditions can give misleading results.Cold Cylinder
Use the exhaust temperature scanner to view the temperatures of each individual cylinder. Compare the temperature readings in order to identify a cold or misfiring cylinder. Refer to Systems Operation/Testing and Adjusting, KENR5473, "Exhaust Temperature Module" for information related to use of the exhaust temperature scanner.If there is an indication of a misfiring cylinder, check the following components for problems:
Spark plugs
Extenders
Ignition transformers
Primary wiring for the ignitionInspect each of the extenders for signs of pin holes and/or of electrical arcing.Refer to Troubleshooting, "Ignition Secondary - Test".Electrical Connectors or Power Supply
There may be an intermittent interruption of power that is causing the symptom. Check the wiring harnesses and the connectors. Inspect the connectors in each of the junction boxes. Inspect the power supply connections and the ground connections.Inspect the wiring from the power supply to the Electronic Control Modules (ECM). Refer to Troubleshooting, "Electrical Power Supply - Test" for information that is related to the wiring harnesses and connectors.Ignition System
Inspect the ignition transformers for the following conditions: loose connections, moisture, short circuits and open circuits. Inspect the primary wiring and the secondary electrical connections.Ensure that the correct transformers and spark plugs are installed on the engine. Inspect the extenders for signs of pin holes and of electrical arcing. Check the spark plugs for fouling, correct gap adjustment, and moisture.Maintain the spark plug according to the engine Operation and Maintenance Manual.Incorrect Base Timing
Verify that the base timing is correct. Refer to Systems Operation/Testing and Adjusting, "Ignition Timing - Adjust".Fuel Supply
Use Cat ET to check that the engine fuel parameters are correct for the fuel that is being used. If necessary, perform fuel analysis in order to confirm the fuel quality.Verify that the fuel pressure is correct. When possible, interview the operator in order to determine if fuel quality is in question. Try to determine if the source of the fuel has been changed.Ensure that fuel is supplied at a sufficient pressure that is stable. Check that the size of the fuel line is sufficient. Inspect the fuel system for leaks.The following conditions can affect engine starting:
Low fuel pressure
High fuel pressure
Poor fuel qualityInspect the following fuel system components:
Fuel filter
Gas pressure regulator
Gas shutoff valve
Fuel metering valveVerify that the system components are operating correctly.Repair suspect components. Replace the fuel filter, if necessary.Inspect the fuel system for debris or moisture buildup. Repair and/or replace as necessary.Incorrect Air/Fuel Ratio
An air/fuel mixture that is too rich or too lean will have an adverse effect on engine operation. Verify that the exhaust emissions are correct. Refer to Troubleshooting, "Nitrogen Oxide Sensor - Calibrate".Be sure to use an accurate instrument for your measurements. Use of instrumentation that is not properly calibrated can lead to an improper diagnosis of the problem.A change in the fuel energy content will change the air/fuel ratio. Obtain a fuel analysis.If the fuel analysis is as expected, inspect the NOX sensor port in the flower pot for plugging. If necessary, clean the port. If the problem persists, refer to Troubleshooting, "Detonation Occurrence".The fuel supply pressure must be 876 to 1289 mbar absolute or 12.705 to 18.695 PSI. The gas differential pressure (delta-p) should be between 69 and 345 mbar. Delta-p below this range is allowed during cranking and idle conditions, but accuracy of the valve will be reduced. For delta-p above 276 mbar, flow accuracy will also decrease, and a reduction in valve stability may occur. Minimum proof pressure for the fuel metering valve is 0.52 bar gauge. Minimum burst pressure for the fuel metering valve is 1.72 bar gauge.Incorrect Governor Adjustment
The governor parameters must be programmed with the values that provide stable operation. Refer to Systems Operation/Testing and Adjusting, "Engine Governing - Adjust".Compressor Bypass Valve
The compressor bypass valve and the compressor bypass actuator must be installed properly in order to provide stable operation. Inspect the mechanical condition of the components. Refer to the Disassembly and Assembly for information that is related to the correct installation of the compressor bypass valve and the compressor bypass actuator.Exhaust Bypass Valve
An improperly adjusted exhaust bypass valve can affect engine performance. If the engine has experienced a change in the operating load, the operating altitude, or the ambient temperature check the setting of the exhaust bypass valve. Refer to Systems Operation/Testing and Adjusting, "Exhaust Bypass Valve - Adjust" for details.Air Inlet Restriction
The maximum allowable air inlet restriction is 3.75 kPa (15 inches of H2O). If the air inlet restriction is higher than the specification, clean the filter element or install a new filter element. Check the restriction again. If the restriction remains too high, inspect the air inlet piping for obstructions.For more information, refer to Systems Operation/Testing and Adjusting, "Restriction of Air Inlet and Exhaust". Also, refer to Installation Guide, LEBW5339, "G3500 GAS ENGINES APPLICATION & INSTALLATION GUIDE".Exhaust Restriction
Measure the exhaust restriction during engine operation with a load. For data that is specific to your engine, refer to Installation Guide, LEBW5339, "G3500 GAS ENGINES APPLICATION & INSTALLATION GUIDE". Also, refer to the engine performance data sheet.Investigate the cause of the exhaust restriction. Perform adjustments and/or repairs, as needed.Throttle Valve Differential Pressure Sensor
Verify that the throttle valve differential pressure sensor is producing the correct signal. Use a 1U-5470 Engine Pressure Gp to measure the throttle valve differential pressure. Compare the reading with the value that is displayed on Cat ET. Replace the sensor, if necessary.Throttle Actuator
Set the engine control to the OFF/RESET position. Remove the electrical power from the engine. Move the throttle plate through the entire range of travel while you feel the motion. If the motion is sticky and/or rough, investigate the cause of the binding. Perform the necessary repairs.Incorrect Valve Lash
Check the valve lash. Refer to Systems Operation/Testing and Adjusting, "Valve Lash and Valve Bridge Adjustment" for information that is related to adjusting the valve lash for the engine.Cylinder
Parts service EVINRUDE:
5005968