BRP EVINRUDE E-TEC E40DPLAB Series Manuals

Manuals and User Guides for BRP EVINRUDE E-TEC E40DPLAB Series. We have 1 BRP EVINRUDE E-TEC E40DPLAB Series manual available for free PDF download: Service Manual

BRP EVINRUDE E-TEC E40DPLAB Series Service Manual (422 pages)

Brand: BRP | Category: Engine | Size: 36.44 MB

S M Ervice Anual Contents

2
Routine Service

19
- Inspection and Maintenance Schedule
  
  20
- Lifting the Outboard
  
  21
- Outboard Rigging Connections
  
  21
- Battery and Battery Connections
  
  28
- Oetiker Clamp Servicing
  
  29
- Adjustments
  
  31
- Operational Checks
  
  37
- Cooling System
  
  38
  - Engine Flushing
    39
  - Running the Outboard Using a Hose and Flushing Adapter
    40
- Lubrication
  
  41
  - Steering System
    41
  - Tiller Handle
    41
  - Swivel Bracket and Trailering Bracket
    42
  - Tilt Tube
    42
  - Throttle and Shift Linkage
    42
  - Propeller Shaft
    43
  - Gearcase Lubricant
    43
  - Trim and Tilt
    45
- Spark Plugs
  
  46
  - Indexing
    46
- Fuel and Oil Systems
  
  47
  - Fuel Filter
    47
  - Oil Filters and Oil Reservoir
    47
  - Air Silencer
    47
  - Hoses and Connections
    47
- Anti-Corrosion Protection
  
  48
- Storage
  
  49
  - Fuel System Treatment
    49
  - Internal Engine Treatment
    49
  - Additional Recommendations
    50
- Pre-Season Service
  
  50
- Submerged Engines
  
  51
Engine Cover Service

53
- Lower Cover Service
  54
  - Lower Cover Removal
    54
  - Lower Cover Installation
    55
  - Latch Handle Installation
    56
  - Trim Switch Installation
    56
- Upper Cover Service
  54
  - Latch Hook Installation
    54
Engine Management Module (Emm)

57
- Description
  58
  - Emm Functions
    58
  - Emm Connections
    58
  - Led Indicators
    58
- Emm Inputs and Outputs Diagram
  59
- Internal Sensors
  60
  - Emm Temperature Sensor
    60
  - 55 V Circuit Sensor
    60
  - 5 V Circuit Sensor
    61
  - Barometric Pressure Sensor
    61
- External Sensors
  61
  - Air Temperature Sensor
    61
  - Engine Temperature Sensor
    61
  - Low Oil Switch
    62
  - Throttle Position Sensor
    63
  - Crankshaft Position Sensor
    63
  - Neutral Switch
    63
- Internal Emm Functions
  64
- Engine Monitor System
  65
- Shutdown Mode
  66
- Warning System
  66
- Diagnostic Software Functions
  67
  - Communication
    67
  - Static Information
    68
  - Dynamic Information
    68
  - Occurred Service Codes (Faults)
    69
  - Active Faults
    69
  - Historical Faults
    69
  - Static Tests
    69
  - Dynamic Tests
    70
  - Oil Control Settings
    70
  - Tiller/Remote Programming
    71
  - Ignition Timing
    71
  - Tps Calibration
    72
  - Idle Speed Control
    72
  - Fuel Injector Servicing
    72
  - Reports
    73
  - Software Replacement
    73
  - Emm Transfer
    74
- Emm Servicing
  74
  - Removal
    74
  - Installation
    75
System Analysis

77
- Diagnostic Procedures
  
  78
  - Visual Inspections
    78
  - Operational Inspections
    78
  - Troubleshooting
    79
- Dynamic Tests
  
  80
  - Cylinder Drop Tests
    80
  - Fuel Control Adjustment
    80
  - Inductive Amp Meter Test
    80
- Emm Led Indicators
  
  81
  - Key on
    81
    
    Starting
    81
    
    Running
    82
- Ignition Output Tests
  
  83
  - Required Ignition Systems
    83
  - Wiring Inspection
    83
  - Crankshaft Position Sensor (Cps) Test
    84
  - System Voltage Test
    84
  - Static Ignition Test
    85
  - Running Ignition Tests
    86
  - Ignition Control Circuit Tests
    87
  - Ignition Coil Tests
    87
  - Capacitor Test
    87
- Fuel Delivery Tests
  
  88
  - Fuel Pump Static Test
    88
  - Fuel Injector Static Test
    88
  - Running Fuel System Tests
    89
- Exhaust Water Valve (60Hp)
  
  90
  - Exhaust Water Valve Static Test
    90
  - Exhaust Water Valvedynamic Test
    90
Electrical and Ignition

91
- Service Chart
  92
- Ignition System Circuit Diagram, 40 - 60 Hp
  94
- Ignition System Circuit Diagram, 75 - 90 Hp
  95
- Electrical Harness Connections
  96
- Fuse
  98
- Ground Circuits
  98
- Sensor Tests
  99
- Stator Tests
  101
  - Stator Resistance Tests
    101
  - Stator Voltage Output Test
    101
- Charging System Tests
  102
- Electric Start Circuit
  104
- Electric Start Tests
  106
- Remote Control Switch Tests
  108
- Exhaust Water Valve Test
  110
- Tilt/Trim Relay Test
  110
- Systemcheck CIRCUIT TESTS
  111
- Tachometer Circuit Tests
  113
- Flywheel and Stator Servicing
  114
  - Flywheel Removal
    114
  - Stator Service
    115
  - Flywheel Installation
    115
- Ignition Coil Servicing
  116
  - Ignition Coil Removal
    116
  - Ignition Coil Installation
    116
- Timing Adjustments
  117
  - Timing Pointer
    117
  - Timing Verification
    118
  - Tps Calibration
    118
- Electric Starter Servicing
  119
  - Starter Removal
    119
  - Starter Installation
    119
- Connector Servicing
  120
  - Connectors
    120
  - Amp Connectors
    121
  - Packard Connectors
    123
Fuel System

125
- Service Chart
  
  126
- Fuel System Hose Routing
  
  130
- Fuel System Circuit Diagrams
  
  132
- Fuel System Requirements
  
  134
  - Regulations and Guidelines
    134
  - Portable Fuel Tanks
    134
  - Fuel Flow Requirements
    134
  - Fuel Requirements
    135
- Components
  
  136
  - Fuel Lift Pump
    136
  - Fuel Filter
    136
  - Vapor Separator
    136
  - Fuel Circulation Pump
    138
  - Fuel Manifolds
    138
  - Fuel Injectors
    138
- Fuel System Priming
  
  140
  - Vent Line Clamp
    140
  - Priming the Fuel System
    140
- Fuel System Tests
  
  141
  - Fuel System Pressure Test
    141
  - Pressure Regulator Test
    142
  - Vapor Separator Vent Check
    142
  - Fuel Injector Pressure Test
    142
  - Fuel Injector Resistance Test
    143
  - Circulation Pump Resistance Test
    143
  - Lift Pump Pressure Test
    143
  - Lift Pump Vacuum Test
    144
  - Lift Pump Diaphragm Test
    145
  - Anti-Siphon Valve Test
    145
- Fuel Component Servicing
  
  146
  - Relieving Fuel System Pressure
    146
  - Fuel Filter Service
    147
  - Fuel Lift Pump Service
    147
  - Vapor Separator Service
    148
  - Fuel Manifold Service
    149
  - Fuel Injector Service
    150
  - Intake Manifold Service
    154
Oiling System

157
- Service Chart
  158
- Oil Supply Diagrams
  160
- Oil Recirculation Diagrams
  162
- Oiling System Circuit Diagram
  163
- Components
  164
  - Oil Tank Assembly
    164
  - Oil Injection Pump
    165
  - Electrical Circuit (55 V)
    165
  - Low Oil Warning
    166
  - NO OIL Warning
    166
  - Cylinder and Crankcase
    166
  - Oil Recirculation System
    167
- Oil System Requirements
  164
  - Recommended Lubricants
    164
- Oil Control Settings
  168
  - Oil Injection Rate
    168
  - Break-In Oiling
    169
  - Oil Supply Priming
    169
- Oiling System Tests
  170
  - Oil Injection Pump Voltage Tests
    170
  - Oil Injection Pump Resistance Test
    171
  - Oil Injection Pump Function Test
    172
  - Oil Injection Fittings Flow Test
    172
  - Low Oil Sending Unit Test
    172
- Oil Component Servicing
  173
  - Oil Distribution Hoses
    173
  - Oil Tank Assembly
    173
  - Oil Injection Pump
    175
Cooling System

177
- Hose Routing and Water Flow Diagrams
  
  178
- Components
  
  180
  - Water Pump and Intakes
    180
  - Exhaust Housing
    180
  - Water Supply Tube
    180
  - Adapter/Inner Exhaust Housing
    181
  - Pressure Relief Valve
    181
  - Thermostat
    181
  - Block Venting
    182
  - Water Pressure Connection
    182
- Operation
  
  183
  - Cylinder Block / Cylinder Head Cooling
    183
  - Emm and Vapor Separator Cooling
    183
- Engine Temperature Check
  
  184
  - Software Method
    184
  - Pyrometer Method
    184
  - Idle Operating Temperature Troubleshooting (below Range)
    185
- Thermostat Servicing
  
  186
  - Disassembly
    186
  - Inspection
    187
  - Assembly
    187
- Temperature Sender Servicing
  
  186
  - Removal
    186
  - Installation
    186
- Pressure Relief Valve Servicing
  
  187
  - Disassembly
    187
  - Inspection
    188
  - Assembly
    188
Powerhead

189
- Service Chart
  
  190
- Powerhead Removal
  
  194
  - 2-Cylinder Models
    194
  - 3-Cylinder Models
    196
- Compression Testing
  
  194
- Powerhead Disassembly
  
  197
  - Systems Removal
    197
  - Throttle Linkage Removal
    198
  - Shift Linkage Removal
    198
  - Crankcase Disassembly
    199
  - Cylinder Head Removal
    200
  - Connecting Rods and Pistons
    200
  - Crankshaft Removal
    201
- Cylinder Block Cleaning
  
  204
- Powerhead Inspection
  
  205
- Powerhead Assembly
  
  207
  - Crankshaft Assembly
    207
  - Pistons and Connecting Rods
    209
  - Cylinder Head Installation
    211
  - Crankshaft and Connecting Rod Installation
    212
  - Crankcase Assembly
    215
  - Shift Linkage Installation
    216
  - Throttle Linkage Installation
    217
  - Final Powerhead Assembly
    218
- Upper Mount Servicing (3-Cylinder)
  
  219
- Powerhead Installation
  
  220
  - Powerhead Mounting - 2-Cylinder Models
    220
  - Powerhead Mounting - 3-Cylinder Models
    222
  - Shift Linkage Adjustment
    224
  - Final Adjustments
    224
- Powerhead Views
  
  225
  - 2-Cylinder Port Models
    225
  - 3-Cylinder Port Models
    232
Midsection

237
- Service Charts
  
  238
- Tilt Tube, 75 - 90 Hp
  
  244
  - Removal
    244
  - Installation
    245
- Exhaust Housing, 40 - 60 Hp
  
  246
  - Exhaust Housing Removal
    246
  - Exhaust Water Valve (60 Hp)
    247
  - Exhaust Relief Muffler
    247
  - Exhaust Housing Installation
    248
- Exhaust Housing, 75 - 90 Hp
  
  249
  - Exhaust Housing Removal
    249
  - Lower Mount Service
    249
  - Exhaust Housing Installation
    250
  - Exhaust Housing Disassembly
    251
  - Cleaning and Inspection
    252
  - Exhaust Housing Assembly
    252
- Stern Bracket, 40 - 60 Hp Power Tilt
  
  254
  - Stern Bracket Disassembly
    254
  - Stern Bracket Assembly
    255
- Stern Bracket, 75 - 90 Hp Power Tilt
  
  256
  - Stern Bracket Disassembly
    256
  - Stern Bracket Assembly
    259
- Stern Bracket, 40 Hp Manual Tilt
  
  261
  - Clamp Screw Service
    261
  - Stern Bracket Disassembly
    261
  - Stern Bracket Assembly
    264
  - Tilt Assist Cylinder
    267
- Tiller Handle Service - Standard
  
  268
  - Removal
    268
  - Disassembly
    269
  - Inspection
    271
  - Assembly
    271
  - Installation
    273
  - Throttle Cable Adjustment
    273
- Tiller Handle Service - Long Handle
  
  274
  - Removal
    274
  - Disassembly
    275
  - Inspection
    278
  - Assembly
    278
  - Installation
    282
  - Control Cable Installation
    283
Gearcase

285
- Service Charts
  
  286
- Gearcase Types, 75 - 90 Hp
  
  289
- Propeller Service
  
  289
- Gearcase Leak Test
  
  291
- Gearcase Service, 40 - 60 Hp Models
  
  292
- Gearcase Removal and Installation
  
  292
- Water Pump Service
  
  294
- Shift Rod Adjustment
  
  296
- Gearcase Disassembly
  
  297
- Shifter, Bearing and Seal Service
  
  301
- Driveshaft Shimming
  
  308
- Gearcase Assembly
  
  309
- Gearcase Service, 75 - 90 Hp Models
  
  314
- Gearcase Removal and Installation
  
  314
- Water Pump Service
  
  316
- Shift Rod Adjustment
  
  319
- Gearcase Disassembly
  
  320
  - Pre-Disassembly Inspection
    320
  - Propeller Shaft Bearing Housing Removal
    321
  - Pinion Gear and Driveshaft Removal
    321
  - Driveshaft Service
    323
  - Shift Housing, Gear and Propeller Shaft Removal
    324
  - Water Intake Screens
    324
- Gearcase Housing Inspection
  
  324
- Shifter, Bearing and Seal Service
  
  325
- Driveshaft Shimming
  
  333
- Gearcase Assembly
  
  334
Trim and Tilt

339
- Service Charts
  
  340
- Service Chart
  
  341
- System Description
  
  342
  - Manual Adjustment
    342
  - Trailering Bracket and Tilt Support
    342
- Routine Inspections
  
  344
  - General
    344
  - Reservoir Fluid
    344
  - Manual Release Valve
    344
  - Stern Brackets
    344
- Troubleshooting
  
  344
- Electrical Circuit Tests
  
  345
  - Relay Testing
    345
  - Trim and Tilt Motor Current Draw Test
    345
  - Trim and Tilt Motor no Load Test
    346
  - Trim Gauge Test
    347
  - Trim Sender Test
    347
- Trim and Tilt Replacement
  
  348
  - Removal
    348
  - Installation
    350
- Trim and Tilt Service
  
  352
  - Manual Release Valve
    352
  - Piston Seal and End Cap
    354
  - Trim Motor
    360
Manual Starter

363
- Service Chart
  364
- Recoil Starter Disassembly
  365
- Recoil Starter Removal
  365
- Recoil Starter Assembly
  367
- Recoil Starter Cleaning and Inspection
  367
- Recoil Starter Installation
  371
Safety

373
- Marine Products and the Safety of People Who Use Them
  375
- Marine Products and the Safety of People Who Fix Them
  389
  - Handling Outboards
    389
  - Handling Lead/Acid Batteries
    393
  - Gasoline - Handle with Care
    394
  - Hazardous Products
    395
  - Safety Awareness Test
    396

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BRP EVINRUDE E-TEC E40DPLAB Series Manuals

BRP EVINRUDE E-TEC E40DPLAB Series Service Manual (422 pages)

Table of Contents

S M Ervice Anual Contents

Routine Service

Inspection and Maintenance Schedule

Lifting the Outboard

Outboard Rigging Connections

Battery and Battery Connections

Oetiker Clamp Servicing

Adjustments

Operational Checks

Cooling System

Lubrication

Spark Plugs

Fuel and Oil Systems

Anti-Corrosion Protection

Storage

Pre-Season Service

Submerged Engines

Engine Cover Service

Engine Management Module (Emm)

System Analysis

Diagnostic Procedures

Dynamic Tests

Emm Led Indicators

Ignition Output Tests

Fuel Delivery Tests

Exhaust Water Valve (60Hp)

Electrical and Ignition

Fuel System

Service Chart

Fuel System Hose Routing

Fuel System Circuit Diagrams

Fuel System Requirements

Components

Fuel System Priming

Fuel System Tests

Fuel Component Servicing

Oiling System

Cooling System

Hose Routing and Water Flow Diagrams

Components

Operation

Engine Temperature Check

Thermostat Servicing

Temperature Sender Servicing

Pressure Relief Valve Servicing

Powerhead

Service Chart

Powerhead Removal

Compression Testing

Powerhead Disassembly

Cylinder Block Cleaning

Powerhead Inspection

Powerhead Assembly

Upper Mount Servicing (3-Cylinder)

Powerhead Installation

Powerhead Views

Midsection

Service Charts

Tilt Tube, 75 - 90 Hp

Exhaust Housing, 40 - 60 Hp

Exhaust Housing, 75 - 90 Hp

Stern Bracket, 40 - 60 Hp Power Tilt

Stern Bracket, 75 - 90 Hp Power Tilt

Stern Bracket, 40 Hp Manual Tilt

Tiller Handle Service - Standard

Tiller Handle Service - Long Handle

Gearcase

Service Charts

Gearcase Types, 75 - 90 Hp

Propeller Service

Gearcase Leak Test

Gearcase Service, 40 - 60 Hp Models

Gearcase Removal and Installation

Water Pump Service

Shift Rod Adjustment

Gearcase Disassembly

Shifter, Bearing and Seal Service