5007805 EVINRUDE Service Manual - English

Fuel System Inspection
A problem with the components that send fuel to the engine can cause low fuel pressure. This can decrease engine performance. 1. Check the fuel level in the fuel tank. Look at the cap for the fuel tank to make sure the vent is not filled with dirt.2. Check the fuel lines for fuel leakage. Be sure the fuel supply line does not have a restriction or a bad bend.3. Install a new fuel filter. Clean the fuel screen located in the inlet valve of the fuel transfer pump.4. Remove any air that may be in the fuel system. Open the drain valve on the fuel injection pump housing. Operate the fuel priming pump until fuel without air comes from the drain lines. Close the drain valve.To remove air from the fuel injection lines, loosen the fuel line nuts 1/2 turn. Move the governor lever to the low idle position. Crank the engine with the starter motor until fuel without air comes from the fuel line connections. Tighten the fuel line nuts.Check Engine Cylinders Separately
An easy check can be made to find the cylinder that runs rough (misfires) and causes black smoke to come out of the exhaust pipe.Run the engine at the speed that is the roughest. Loosen the fuel line nut at a fuel injection pump. This will stop the flow of fuel to that cylinder. Do this for each cylinder until a loosened fuel line is found that makes no difference in engine performance. Be sure to tighten each fuel line nut after the test before the next fuel line nut is loosened. Check each cylinder by this method. When a cylinder is found where the loosened fuel line nut does not make a difference in engine performance, test the injection pump and fuel injection nozzle for that cylinder.Temperature of an exhaust manifold port, when the engine runs at low idle speed, can also be an indication of the condition of a fuel injection nozzle. Low temperature at an exhaust manifold port is an indication of no fuel to the cylinder. This can possibly be an indication of a nozzle with a defect. Extra high temperature at an exhaust manifold port can be an indication of too much fuel to the cylinder, also caused by a nozzle with a defect.The most common defects found with the fuel injection valves are: 1. Carbon on tip of the nozzle or in the nozzle orifice.2. Orifice wear.3. Dirty nozzle screen.Fuel Injector Testing
Testing of the injectors must be done off the engine. Use 5P4150 Nozzle Testing Group. For use of the 5P4150 Nozzle Testing Group, refer to Special Instruction, Form No. SEHS7292.Fuel Injection Lines
Fuel from the fuel injection pumps goes to the fuel injection nozzles through the fuel injection lines.When fuel injection lines are disconnected or removed, always put caps or plugs on the ends to keep dirt out of the lines. When fuel injection lines are installed, be sure all clamps and dampers are installed in their original location.Each fuel injection line of an engine has a special design and must be installed in a certain location. When fuel injection lines are removed from an engine, put identification marks or tags on the fuel lines as they are removed, so they can be put in the correct location when they are installed.The nuts that hold a fuel injection line to an injection nozzle and injection pump must be tightened to the correct torque. If the nut is loose, fuel will leak from the connection. If the nut is tightened too tight, the inside diameter of the line will become smaller and cause a restriction to the flow of fuel in the line. Use a torque wrench and a 5P144 Fuel Line Socket to tighten the fuel injection line nuts to 42 7 N m (31 5 lb ft).Fuel Injection Pumps
When injection pumps, sleeves and lifters are removed from the injection pump housing, keep the parts of each pump together so they can be installed back in their original location.Be careful when disassembling injection pumps. Do not damage the surface on the plunger. The plunger, sleeve and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel or sleeve of another pump. If one part is worn, install a complete new pump assembly. Be careful when putting the plunger in the bore of the barrel or sleeve.When an injection pump is installed correctly, the plunger is through the sleeve and the adjustment lever is engaged with the groove on the sleeve. The bushing that holds the injection pump in the pump housing must be kept tight. Tighten the bushing to 80 7 N m (60 5 lb ft). Damage to the housing will result if the bushing is too tight. If the bushing is not tight enough, the pump will leak.
Air Inlet Pipe
If the sleeves on one or more of the fuel injection pumps have been installed wrong, damage to the engine is possible if cautions are not taken at first starting. When the fuel injection pumps have been removed and installed with the fuel injection pump housing on engine, take the following cautions when first starting the engine.
a. Remove the air cleaner leaving the air inlet pipe open as shown.b. Set the governor control at low idle.
Be careful when plate is put against air inlet opening. Due to excessive suction, the plate can be pulled quickly against air inlet pipe. To avoid crushed fingers, do not put fingers between plate and air inlet pipe.
c. Start the engine, and if engine starts to overspeed (run out of control), put a steel plate over the air inlet as shown to stop the engine.
Stopping The EngineFinding Top Center Compression Position For No. 1 Piston
No. 1 piston at top center (TDC) on the compression stroke is the starting point for all timing procedures.1. Remove fitting (1) from the timing hole (3) in the front cover. Put