Fuel System Tests; Fuel System Pressure Test - Evinrude E-Tec 40 HP Service Manual

FUEL SYSTEM TESTS

A
WARNING
Use caution when working on any pres-
surized fuel system. Wear safety glasses
and work in a well ventilated area. Extin-
guish all smoking materials and make cer-
tain no open flames or ignition sources
exist. Before starting any fuel system ser-
vice, carefully relieve fuel system pres-
sure. Failure to properly relieve fuel
system pressure can result in spraying
fuel and/or excessive fuel spillage during
servicing. Fuel is flammable and can be
explosive under certain conditions.

Fuel System Pressure Test

Relieve fuel system pressure. Refer to Relieving
Fuel System Pressure on p. 142.
A
WARNING
Protect against hazardous fuel spray.
Before starting any fuel system service,
carefully relieve fuel system pressure.
After relieving fuel system pressure, install a 0 to
60 p si (0 to 415 kPa ) Fuel Pressur e Gau ge,
P/N 5007100 or equivalent, to the upper fuel pres-
sure test fitting.
1
1. Test fitting
2. Fuel pressure gauge
START outboard and che ck pressu re. Syste m
pressure should be 20 to 35 psi (138 to 241 kPa).
Shut OFF outbo ard. Mo nitor pr essure gaug e.
Pressure should not drop below 15 psi (103 kPa).
IMPORTANT:
fuel system and crank outboard; check circulation
pump operation; check fuel system pressure.
Results:
Normal pressure:
Observe pressure reading after outboard is shut
•
OFF
Refer to Lift Pump Pressure Test on p. 139
•
Pressure drops after outboard is shut OFF:
Check for leaking fuel injector.
•
Check for leaking pressure regulator.
•
Check for external fuel system leak.
•
High pressure:
Check for re stricted filter or fuel return fitting of
•
vapor separator, damaged pressure regulator in
vapor sep arator, or restricted fuel return mani-
fold.
Low pressure:
Check fuel supply to fuel lift pump. Refer to Lift
•
Pump Vacuum Test on p. 140. Higher vacuum
readings indicate restrictions in the fuel supply.
Repair or replace as needed.
Restricted fuel filter/water separator assembly.
•
Lift pump not supp lying enou gh fuel to vap or
•
separator. Refer to Lift Pump Pressure Test
on p. 139.
If the above tests are good and vapor separator
•
remains full of fu el, check for da maged circula-
tion pump. Replace vapor separator assembly.
2
No pressure:
Check electrical circuit and ground connections
•
for circulation pump.
If volt age is present and pump does
•
repair connection or replace vapor separator
assembly.
Relieve fuel system pressure before removing fuel
006655
pressure gauge. Refer to Relieving Fuel System
Pressure on p. 142.
FUEL SYSTEM
FUEL SYSTEM TESTS
If outb oard does not run, prime
7
not run,
137