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Evinrude E-TEC E150DPXSCF manual available for free PDF download: Service Manual
Evinrude E-TEC E150DPXSCF Service Manual (445 pages)
E-TEC series
Brand:
Evinrude
| Category:
Engine
| Size: 31.89 MB
Table of Contents
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 Dropped Overboard (Not Running)
90
Engine Dropped Overboard (Running)
90
Engine Dropped Overboard (in Salt Water)
90
Prolonged Submersion (Fresh or Salt Water)
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
Crankshaft Position Sensor (Cps) Test
136
Throttle Position Sensor (Tps) Test
136
Engine Temperature Sensor Test
137
Air Temperature Sensor (At) Test
137
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
Gearcase Disassembly
309
Pre-Disassembly Inspection
309
Propeller Shaft Bearing Housing Removal - "S2", "O", "L" and "M" Type
310
Propeller Shaft Bearing Housing Removal - "L2" and "M2" Type
311
Pinion Gear and Driveshaft Removal - "S2" Type
312
Standard Rotation
312
Pinion Gear and Driveshaft Removal - "O", "L", "L2", "M" and "M2" Type
315
Driveshaft Service
316
Shift Housing, Gear and Propeller Shaft Removal
317
Water Intake Screens
317
Gearcase Housing Inspection
318
Shifter, Bearing and Seal Service
318
Shift Housing Disassembly
318
Shift Housing Assembly
319
Pinion Bearing Removal
321
Pinion Bearing Installation
322
Driveshaft Bearing Housing Service
323
Propeller Shaft Bearing Housing Service
324
Driveshaft Shimming
327
Gearcase Assembly
329
Shift Housing, Gear, and Propeller Shaft Installation
329
Shift Rod Cover
329
Water Intake Screens
329
Pinion Gear and Driveshaft Installation - "S2" Type
331
Pinion Gear and Driveshaft Installation - "O", "L"' "L2", "M" and "M2" Type
334
Propeller Shaft Bearing Housing and Gear Installation - "S2", "O", "L" and "M" Type
336
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
Gearcase Disassembly
340
Pre-Disassembly Inspection
340
Propeller Shaft Bearing Housing Removal - "M2" Type
340
Propeller Shaft Bearing Housing Removal - "O" and "M" Type
340
Pinion Gear Removal and Driveshaft Servicing
341
Shift Housing, Gear and Propeller Shaft Removal
342
Water Intake Screens
342
Gearcase Housing Inspection
342
Shifter, Bearing and Seal Servicing
343
Counter Rotation
343
Shift Housing Disassembly
343
Shift Housing Assembly
344
Pinion Bearing
346
Propeller Shaft Bearing Housing and Forward Gear - "O" Type
346
Propeller Shaft Bearing Housing and Forward Gear - "M" and "M2" Type
350
Driveshaft Shimming
353
Gearcase Assembly
355
Pinion Gear and Driveshaft Installation
355
Shift Housing, Gear, and Propeller Shaft Installation
355
Shift Rod Cover
355
Water Intake Screens
355
Propeller Shaft Bearing Housing and Gear Installation - "O" and "M" Type
355
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
Marine Products and the Safety of People Who Use Them
397
Outboard Shift Systems and Safety
398
Outboard Speed Control System and Safety
399
Outboard Steering Control System and Safety
400
Outboard Fuel, Electrical System, and Safety
402
Outboard Mounting System and Safety
405
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
407
Outboard Emergency Stop System and Safety
408
Summing up
410
Marine Products and the Safety of People Who Fix Them
411
Handling Outboards
411
Handling Lead/Acid Batteries
415
Gasoline - Handle with Care
416
Hazardous Products
417
Safety Awareness Test
418
Trouble Check Chart
429
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