Evinrude E-TEC E115DPLSCR Manuals

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Evinrude E-TEC E115DPLSCR Service Manual (445 pages)

E-TEC series

Brand: Evinrude | Category: Engine | Size: 31 MB

Table of Contents

4
- Safety
  6
- Abbreviations Used in this Manual
  
  8
- Units of Measurement
  
  8
- List of Abbreviations
  
  8
  - Introduction
    8
- Engine Emissions Information
  
  9
- Manufacturer's Responsibility
  
  9
- Dealer's Responsibility
  
  9
- Owner's Responsibility
  
  9
- Epa Emission Regulations
  
  9
- Model Designation
  
  10
- Models Covered in this Manual
  
  11
- Identifying Model and Serial Numbers
  
  11
- Service Specifications
  
  12
- Standard Torque Specifications
  
  14
- Product Reference and Illustrations
  
  14
Special Tools 1

15
- Diagnostic Tools
  16
- Special Tools
  16
- Universal Tools
  16
- Electrical / Ignition Tools
  18
  - Special Tools
    18
- Fuel /Oil System Tools
  19
- Powerhead Tools
  19
- Gearcase Tools
  20
- Trim and Tilt Tools
  24
- Shop Aids
  25
- Notes
  28
Installation and Predelivery

29
- Boat Rigging
  
  30
  - Remote Controls
    30
  - Battery Installation
    31
  - Battery Switches and Multiple Batteries
    32
  - Installation and Predelivery
    32
    
    Auxiliary Battery Charging
    34
    
    Battery and Switch Wiring Diagrams
    35
    
    Fuel System Requirements
    37
    
    Oiling System Set-Up
    39
    
    Cable and Hose Installation
    42
- Outboard Installation
  
  46
  - Hull Preparation
    46
  - Transom Measuring and Drilling
    48
  - Lifting the Outboard
    51
  - Steering Systems
    51
  - Outboard Mounting
    53
- Outboard Rigging
  
  54
  - Cable, Hose, and Wire Routing
    54
  - Control Cable Installation
    55
  - Electrical Harness Connections
    57
  - Water Pressure Gauge
    58
  - Canbus Connections
    58
- Fuel and Oil Priming
  
  60
  - Fuel Requirements
    60
  - Fuel System Priming
    61
  - Oil Requirements
    61
  - Oil Injection Rate
    62
  - Break-In Oiling
    63
  - Oil Supply Priming
    63
- Before Start-Up
  
  65
  - Oil Level
    65
- Running Checks
  
  66
  - Engine Monitoring System
    66
  - Fuel System
    66
  - Emergency Stop / Key Switch
    66
  - Start-In-Gear Prevention
    66
  - Tachometer Pulse Setting
    67
  - Water Pump Overboard Indicator
    67
  - Operating Temperature
    67
  - Break-In
    67
- Propellers
  
  68
  - Propeller Selection
    68
  - Propeller Hardware Installation
    69
- Final Adjustments
  
  70
  - Tilt Limit Switch Adjustment
    70
  - Trim Sending Unit Adjustment
    71
  - Trim Tab Adjustment
    72
  - Dual-Outboard Alignment
    73
- Notes
  
  74
Installation and Predelivery Notes Notes

75
- Inspection and Maintenance Schedule
  
  76
- Anti-Corrosion Protection
  
  77
  - Sacrificial Anodes
    77
  - Testing Procedure - Continuity
    77
  - Metallic Component Protection
    77
  - Exterior Finishes
    77
- Cooling System
  
  78
  - Flushing
    78
  - Maintenance
    78
    
    Additional Maintenance
    79
    
    Water Intake Screens
    79
- Lubrication
  
  79
  - Steering System
    79
  - Swivel Bracket and Trailering Bracket
    80
  - Tilt Tube
    80
  - Throttle and Shift Linkage
    80
  - Propeller Shaft
    81
  - Gearcase Lubricant
    81
  - Trim and Tilt
    83
- Battery and Battery Connections
  
  84
- Fuel and Oil Systems
  
  84
  - Fuel Filter
    84
  - Oil Filters and Oil Reservoir
    85
  - Air Silencer
    85
  - Hoses and Connections
    85
- Spark Plugs
  
  86
  - Indexing
    86
- Exhaust Pressure Fitting
  
  87
  - Operation Test
    87
  - Cleaning
    87
- Storage
  
  88
  - Fuel System Treatment
    88
  - Internal Engine Treatment
    88
  - Additional Recommendations
    89
- Pre-Season Service
  
  89
  - Outboard Mounting Bolts
    89
  - Gearcase Lubricant
    89
  - Battery(S)
    89
  - Power Trim and Tilt
    89
  - Operational Checks
    89
- Submerged Engines
  
  90
Engine Cover Service

91
- Upper Cover Service
  92
  - Latch Hook Installation
    92
  - Upper Cover Cap Replacement
    92
- Lower Cover Service
  93
  - Lower Cover Removal
    93
  - Lower Cover Installation
    93
  - Latch Handle Installation
    94
  - Trim Switch Installation
    94
- Engine Cover Service
  94
Table of Contents

95
- Description
  
  96
  - Emm Connections
    96
  - Emm Functions
    96
- Emm Inputs and Outputs Diagram
  
  97
  - Engine Management Module (Emm)
    98
    
    Barometric Pressure Sensor
    99
    
    Exhaust Pressure Sensor
    99
- Internal Sensors
  
  98
  - Emm Temperature Sensor
    98
  - 55 V Circuit Sensor
    98
- External Sensors
  
  99
  - Air Temperature Sensor
    99
  - Oil Pressure Sensor
    100
  - Throttle Position Sensor
    101
  - Crankshaft Position Sensor
    101
  - Neutral Switch (V4 Models)
    101
- Internal Emm Functions
  
  102
  - Start Assist Circuit (Sac)
    102
  - Rom Verification
    102
  - Idle Controller
    102
  - Rpm Limiter
    102
  - Exhaust Valve (V4 Models)
    102
  - Engine Monitor and Warning Systems
    102
  - Fault Code Creation and Storage
    102
- Engine Monitoring System
  
  103
  - Engine Running
    103
  - Service Mode
    103
- Shutdown Mode
  
  104
- Warning System
  
  104
- Diagnostic Software Functions
  
  105
  - Communication
    105
  - Static Information
    105
  - Dynamic Information
    106
  - Stored Service Codes (Faults)
    106
  - Hard Faults
    106
  - Persistent Faults
    106
  - Static Tests
    106
  - Dynamic Tests
    107
  - Oil Control Settings
    108
  - Tiller/Remote Programming
    108
  - Ignition Timing
    109
  - Tps Calibration
    109
  - Fuel Injector Servicing
    110
  - Reports
    110
  - Software Replacement
    111
  - Emm Transfer
    111
- Emm Servicing
  
  112
  - Removal
    112
  - Installation
    112
Table of Contents

113
- Diagnostic Procedures
  
  114
  - Visual Inspections
    114
  - Operational Inspections
    114
  - Troubleshooting
    115
- Dynamic Tests
  
  116
  - Cylinder Drop Tests
    116
  - Fuel Control Adjustment
    116
  - Inductive Amp Meter Test
    116
  - System Analysis
    116
- Emm Led Indicators
  
  117
  - Key on
    117
  - Starting
    117
  - Running
    118
- Ignition Output Tests
  
  119
  - Required Ignition Systems
    119
  - Wiring Inspection
    119
  - Crankshaft Position Sensor (Cps) Test
    120
  - System Voltage Test
    120
  - Ignition Voltage Test
    121
  - Static Ignition Test
    121
  - Running Ignition Tests
    122
  - Ignition Primary Circuit Resistance Test
    123
  - Ignition Coil Tests
    123
  - Capacitor Test
    124
- Fuel Delivery Tests
  
  124
  - Fuel Pump Static Test
    124
  - Fuel Injector Static Test
    125
  - Running Fuel System Tests
    125
- Exhaust Valve (V4 Models)
  
  127
  - Exhaust Valve Static Test
    127
- Notes
  
  128
System Analysis Notes Notes

129
- Service Chart
  130
- Dash Connections, Instrument Harness
  132
- Electrical and Ignition
  132
- Electrical Harness Connections
  133
- Fuse
  135
- Ground Circuits
  135
- Sensor Tests
  136
- Stator Tests
  138
  - Stator Resistance Tests
    138
  - Stator Voltage Output Test
    138
- Charging System Tests
  139
  - 12 V Charging Circuit
    139
  - Auxiliary Battery - Charge Wire
    140
  - 55 V Alternator Circuit
    140
- Electric Start Circuit
  141
- Electric Start Tests
  143
- No Load Current Draw Test
  144
- Remote Control Switch Tests
  145
- Tilt/Trim Relay Test
  147
- Exhaust Valve Relay Tests
  148
- Systemcheck Circuit Tests
  150
  - Check Engine Circuit Test
    151
  - Low Oil Circuit Test
    152
  - No Oil Circuit
    152
- Tachometer Circuit Tests
  152
- Flywheel and Stator Servicing
  153
  - Flywheel Removal
    153
  - Stator Service
    154
  - Flywheel Installation
    154
- Timing Adjustments
  156
  - Timing Pointer
    156
  - Timing Verification
    157
  - Tps Calibration
    158
- Electric Starter Servicing
  158
  - Starter Removal
    158
  - Starter Disassembly
    159
  - Starter Cleaning and Inspection
    161
  - Starter Assembly
    162
  - Starter Installation
    165
- Connector Servicing
  166
Table of Contents

171
- Service Chart
  
  172
  - Fuel System
    174
- Fuel System Hose Routing
  
  175
- Fuel System Circuit Diagram
  
  176
- Components
  
  177
  - Fuel Lift Pump
    177
  - Fuel Filter
    177
  - Vapor Separator
    178
  - Fuel Circulation Pump
    179
  - Fuel Manifolds
    179
  - Fuel Injectors
    179
- Fuel System Tests
  
  180
  - Fuel System Pressure Test
    180
  - Pressure Regulator Test
    181
  - Vapor Separator Vent Check
    181
  - Fuel Injector Pressure Test
    182
  - Fuel Injector Resistance Test
    182
  - Circulation Pump Resistance Test
    183
  - Lift Pump Pressure Test
    183
  - Lift Pump Vacuum Test
    183
  - Lift Pump Diaphragm Test
    184
  - Anti-Siphon Valve Test
    184
- Fuel Component Servicing
  
  185
  - Relieving Fuel System Pressure
    185
  - In-Line Fuel Filter Service
    186
  - Optional Fuel Filter Service
    186
  - Fuel Lift Pump Service
    187
  - Vapor Separator Service
    187
  - Fuel Manifold Service
    188
  - Fuel Injector Service
    189
  - Intake Manifold Service
    192
  - Installation
    193
Table of Contents

195
- Service Chart
  196
- Oiling System Circuit Diagram
  197
- Oil Supply Diagrams - V4
  198
  - Oiling System
    198
- Oil Supply Diagrams - V6
  200
- Oil Recirculation Diagrams - V4
  202
- Oil Recirculation Diagrams - V6
  204
- Components
  206
  - Oil Tank Assembly
    206
  - Oil Injection Pump
    206
  - Oil Pressure Sensor
    206
  - Electrical Circuit (55 V)
    207
  - Low Oil Warning
    207
  - No Oil Warning
    207
  - Cylinder and Crankcase
    207
  - Oil Recirculation System
    208
- Oil Control Settings
  209
  - Oil Priming
    209
  - Oiling Rates
    209
  - Break-In Oiling
    209
- Oiling System Tests
  209
  - Oil Injection Pump Static Test
    209
  - Oil Injection Pump Voltage Test
    210
  - Oil Injection Pump Circuit Resistance Test
    210
  - Oil Supply Vacuum Test
    211
  - Oil Injection Pump Function Test
    212
  - Oil Injection Fittings Flow Test
    212
  - Low Oil Sending Unit Test
    212
- Oil Component Servicing
  213
  - Oil Distribution Hoses
    213
  - Oil Injection Pump
    214
- Notes
  216
Oiling System Notes Notes

217
- Hose Routing and Water Flow Diagrams
  
  218
- Components
  
  220
  - Water Pump and Intakes
    220
  - Water Supply Tube
    220
  - Adapter/Inner Exhaust Housing
    220
  - Cooling System
    220
  - Pressure Relief Valve
    221
  - Thermostats
    221
  - Block Venting
    221
  - Water Pressure Connection
    221
- Operation
  
  222
  - Cylinder Block / Cylinder Head Cooling
    222
  - Emm and Vapor Separator Cooling
    222
- Engine Temperature Check
  
  223
  - Software Method
    223
  - Pyrometer Method
    223
  - Idle Operating Temperature Troubleshooting (below Range)
    224
- Thermostat Servicing
  
  225
  - Disassembly
    225
  - Inspection
    225
  - Assembly
    225
- Pressure Relief Valve Servicing
  
  226
  - Disassembly
    226
  - Inspection
    226
  - Assembly
    226
Table of Contents

227
- Service Chart
  
  228
- Powerhead Removal
  
  230
- Powerhead Disassembly
  
  232
  - General
    232
  - Throttle Linkage Removal
    232
  - Shift Linkage Removal
    232
  - Crankcase Disassembly
    233
  - Cylinder Head Removal
    233
  - Connecting Rods and Pistons
    234
  - Crankshaft Removal
    235
- Cylinder Block Cleaning
  
  237
- Powerhead Inspection
  
  238
  - Cylinder Head
    238
  - Crankshaft
    239
  - Cylinder Bore
    239
  - Pistons
    240
  - Piston Rings
    240
  - Bearings
    240
- Powerhead Assembly
  
  241
  - Crankshaft Assembly
    241
  - Pistons and Connecting Rods
    242
  - Cylinder Head Installation
    244
  - Crankshaft and Connecting Rods
    245
  - Crankcase Assembly
    248
  - Shift Linkage Installation
    250
  - Throttle Linkage Installation
    250
  - Final Powerhead Assembly
    251
- Upper Mount Servicing
  
  252
- Powerhead Installation
  
  253
- Powerhead Views
  
  257
  - V4 Starboard - Hose Routings
    257
  - V4 Port - Hose Routings
    258
  - V4 Starboard
    259
  - V4 Port
    260
  - V4 Front
    261
  - V4 Rear
    262
  - V4 - V6 Top - Hose Routings
    263
  - V4 - V6 Top
    264
  - V6 Starboard - Hose Routings
    265
  - V6 Port - Hose Routings
    266
  - V6 Starboard
    267
  - V6 Port
    268
  - V6 Front
    269
  - V6 Rear
    270
Powerhead Powerhead Views V6 Rear

271
- Service Chart
  
  272
  - Midsection
    274
- Tilt Tube
  
  275
  - Removal
    275
  - Installation
    276
- Exhaust Housing
  
  277
  - Exhaust Housing Removal
    277
  - Exhaust Housing Disassembly
    278
  - Cleaning and Inspection
    279
  - Exhaust Housing Assembly
    279
  - Exhaust Housing Installation
    282
- Stern Bracket
  
  283
  - Stern Bracket Removal
    283
  - Stern Bracket Disassembly
    283
  - Stern Bracket Assembly
    285
- Exhaust Relief Muffler Assembly
  
  288
Gearcase - Standard Rotation

289
- Service Charts
  291
- Gearcase
  292
  - Gearcase Types
    300
  - Gearcase Leak Test
    302
  - Propeller Service
    302
  - Shift Interrupt Switch
    302
  - Gearcase Removal
    303
  - Gearcase Removal and Installation
    303
  - Gearcase Installation
    304
  - Assembly
    306
  - Disassembly
    306
  - Inspection
    306
  - Water Pump Service
    306
  - Shift Rod Adjustment
    308
- Gearcase - Standard Rotation
  
  309
- Propeller Shaft Bearing Housing and Gear Installation - "L2" Type
  
  337
  - Propeller Shaft Bearing Housing and Gear Installation - "M2" Type
    338
    
    Final Assembly and Adjustment
    339
- Gearcase - Counter Rotation
  
  340
- Propeller Shaft Bearing Housing and Gear Installation - "M2" Type
  
  356
  - Final Assembly and Adjustment
    357
  - Notes
    358
Gearcase - Counter Rotation Notes Notes

359
- Service Chart
  
  360
- System Description
  
  362
  - Manual Adjustment
    362
  - Trailering Bracket and Tilt Support
    362
  - Trim and Tilt
    362
- Modes of Operation (Three Piston System)
  
  363
  - Trim-Out / Tilt-Up Mode
    363
  - Tilt-Down / Trim-In Mode
    364
  - Impact Relief
    365
  - Shallow Water Drive Tilt Relief
    366
  - Thermal Expansion Relief
    366
  - Manual Release - up
    367
  - Manual Release - down
    368
- Troubleshooting
  
  369
  - Three Piston System
    369
  - Single Piston System
    373
- Routine Inspections
  
  369
  - General
    369
  - Reservoir Fluid
    369
  - Manual Release Valve
    369
  - Stern Brackets
    369
- Electrical Circuit Tests
  
  373
  - Relay Testing
    373
  - Trim and Tilt Motor Current Draw Tests
    373
  - Trim and Tilt Motor no Load Test
    374
  - Trim Gauge Test
    375
  - Trim Sender Test
    376
- Trim and Tilt Service
  
  376
- Servicing - Three Piston System
  
  379
  - Disassembly
    379
  - Tilt Piston Removal
    382
  - Tilt Piston Identification
    383
  - Tilt Piston Assembly
    383
  - Tilt Rod Assembly
    384
  - Trim Rod Removal
    385
  - Trim Rod Assembly
    386
  - Manifold and Reservoir Installation
    387
  - Trim Rod Installation
    388
  - Tilt Rod Installation
    389
  - Motor Installation
    389
- Servicing-Single Piston System
  
  391
  - Disassembly
    391
  - Assembly
    392
- Adjustments
  
  394
Trim and Tilt Adjustments Adjustments

395

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Evinrude E-TEC E115DPLSCR Service Manual (445 pages)

Table of Contents

Table of Contents

Abbreviations Used in this Manual

Units of Measurement

List of Abbreviations

Engine Emissions Information

Manufacturer's Responsibility

Dealer's Responsibility

Owner's Responsibility

Epa Emission Regulations

Model Designation

Models Covered in this Manual

Identifying Model and Serial Numbers

Service Specifications

Standard Torque Specifications

Product Reference and Illustrations

Special Tools 1

Installation and Predelivery

Boat Rigging

Outboard Installation

Outboard Rigging

Fuel and Oil Priming

Before Start-Up

Running Checks

Propellers

Final Adjustments

Notes

Installation and Predelivery Notes Notes

Inspection and Maintenance Schedule

Anti-Corrosion Protection

Cooling System

Lubrication

Battery and Battery Connections

Fuel and Oil Systems

Spark Plugs

Exhaust Pressure Fitting

Storage

Pre-Season Service

Submerged Engines

Engine Cover Service

Table of Contents

Description

Emm Inputs and Outputs Diagram

Internal Sensors

External Sensors

Internal Emm Functions

Engine Monitoring System

Shutdown Mode

Warning System

Diagnostic Software Functions

Emm Servicing

Table of Contents

Diagnostic Procedures

Dynamic Tests

Emm Led Indicators

Ignition Output Tests

Fuel Delivery Tests

Exhaust Valve (V4 Models)

Notes

System Analysis Notes Notes

Table of Contents

Service Chart

Fuel System Hose Routing

Fuel System Circuit Diagram

Components

Fuel System Tests

Fuel Component Servicing

Table of Contents

Oiling System Notes Notes

Hose Routing and Water Flow Diagrams

Components

Operation

Engine Temperature Check

Thermostat Servicing

Pressure Relief Valve Servicing

Table of Contents

Service Chart

Powerhead Removal