5009001 EVINRUDE Service Manual 15 to 30 HP English

Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to Systems Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Note: Ensure that the engine is stopped before installing and removing Tooling (A) and (B) or carrying out any repair work on the fuel system.
Illustration 1 g02871337
Typical example (1) Primary fuel filter (2) Secondary fuel filter (3) Fuel injection pump (4) Fuel manifold (rail) (5) Electronic unit injector (6) Check valve
Table 2
Position     Measurement     Minimum Pressure     Maximum Pressure    
A     Inlet of fuel injection pump     50 kPa (7.25 psi)     -    
B     Inlet of secondary fuel filter    
400 kPa (58 psi)    
650 kPa (94 psi)    
C     Outlet of secondary fuel filter    
400 kPa (58 psi)    
650 kPa (94 psi)    
D     Injector return line    
30 kPa (4.35 psi)    
80 kPa (11.6 psi)    
E     Return line     -    
20 kPa (2.9 psi)    
Remove all relevant tube assemblies. Refer to Disassembly and Assembly for the correct procedures.
Install Tooling (A) at location (A) . Refer to illustration 1. Install Tooling (B) at locations (B) , (C) , (D) , and (E) . Refer to illustration 1.
Start the engine. Refer to Operation and Maintenance Manual for the correct procedure.
Use Tooling (A) and (B) to measure the pressure values in the order indicated in table 2 at both idle speed and at maximum engine speed with zero load. In both measurement conditions, the values measured must be between the minimum and maximum permissible pressure values.
Use Tooling (A) to measure the pressure value at position (A) . If the pressure value measured is lower than the minimum permissible pressure, check that the primary fuel filter is not restricted. Check that the tube assemblies upstream of the measurement point are not restricted. Check that there are no signs of air infiltration or damage in the tube assemblies and connectors upstream of the inlet of the fuel injection pump. Replace any damaged components.
Use Tooling (B) to measure the pressure value at position (B) . If the pressure value measured is lower than the minimum permissible pressure, check that the fuel injection pump functions correctly. Check for leaks in the circuit. If the pressure value measured is greater than the maximum permissible pressure, check that the lines between the secondary fuel filter and the fuel injection pump are not restricted. Replace any damaged components.
Use Tooling (B) to measure the pressure value at position (C) . If the pressure value measured is lower than the minimum permissible pressure, or if the difference between the value and the value measured in step 6 is greater than 150 kPa (22 psi), check if the secondary fuel filter is restricted. If the pressure value measured is greater than the maximum permissible pressure, check that the tube assemblies between the secondary fuel filter and the fuel injection pump are not restricted. If the problem persists, check that fuel injection pump functions correctly. Replace any damaged components.
Use Tooling (B) to measure the pressure value at position (D) . If the pressure value measured is lower than the minimum permissible pressure, check that there is no leakage from the injector return line. Check that the check valve (6) that is integrated in the injector return line is functioning correctly. If the pressure value measured is greater than the maximum permissible pressure, check that there are no restrictions in the lines of the injector return line. Check that the check valve (6) that is integrated in the injector return line is functioning correctly. If the problem persists, check that the electronic unit injectors are functioning correctly with the electronic service tool. Replace any damaged components.
Use Tooling (B) to measure the pressure value at position (E) . If the pressure value measured is greater than the maximum permissible pressure, check that there are no restrictions in the fuel return lines. Check that the components of the high-pressure fuel system, such as the fuel injection pump, fuel manifold and electronic unit injectors are working correctly by using the electronic service tool test function to identify any faults relative to these components. Replace any damaged components.Note: Check that the manifold connector (7) is functioning correctly. Check that fuel flow is visible in the transparent pipe downstream of the connector (7) .
Remove Tooling (A) and (B) at locations (A) , (B) , (C) , (D) , and (E) .
Install all relevant tube assemblies. Refer to Disassembly and Assembly for the correct procedures.