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BRP
Outboard Motor
Evinrude E-TEC G2
Service Manual
Page 242
BRP Evinrude E-TEC G2 - Page 242
460 pages
Manual
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242
Powerhead
Powerhead Removal
Rear
Remove the following hose clamp
s and hoses:
1.
10.5 mm Rear oil pump(s) hose(s), remove the
supply hose from the oil pump.
2.
15.7 mm T
ee fitting, hose to overboard indica-
tor
, remove hose from tee fitting.
009176
2
1
241
243
Table of Contents
Main Page
Service Manual
2
Table of Contents
2
Table of Contents
3
Safety Notice
4
Abbreviations Used in this Manual
6
Units of Measurement
6
List of Abbreviations
6
Standard Torque Specifications
7
Product Reference and Illustrations
7
Emission-Related Installation Instructions
8
Manufacturer's Responsibility
8
Dealer's Responsibility
8
Owner's Responsibility
8
EPA Emission Regulations
9
EPA Internet Web Site
9
Engine Identification
10
Model Designation
10
Models Covered
11
Service Specifications
12
Routine Service
15
Inspection and Maintenance Schedule
16
Batteries
17
Maintenance
17
Oetiker Clamp Servicing
18
Cooling System
19
Engine Flushing
19
Gearcase Lubricant
20
Propeller Shaft
20
Spark Plugs
22
Fuel and Oil Systems
23
Exhaust Pressure Fitting
24
Anti-Corrosion Protection
25
Storage
26
Lifting the Outboard
28
Pre-Season Service
28
Plug Installation
29
Rigging Information
30
Before Start-Up
38
Operational Checks
39
Propellers
40
Adjustments
42
Engine Mounting Height and Jack Plate Adjustment
42
Engine Water Pressure
43
Fuel System Vacuum
43
Tilt Limit Setting
43
Trim & Tilt
43
I-Trim
44
Trim Gauge Calibration
44
Dynamic Power Steering (DPS)
45
Multiple Outboard Alignment
45
Engine Submerged (in Salt Water)
47
Engine Submerged (Not Running)
47
Engine Submerged (Running)
47
Prolonged Submersion (Fresh or Salt Water)
47
Submerged Engines
47
Filling and Bleeding the Hydraulic Steering System
48
Hydraulic Steering Fluid
48
Single Station / Single Engine Steering Installations
48
Single Station / Multiple Engine Installations
50
Steering System Checks
52
Oetiker Clamp Chart
54
Engine Cover and Frame Service
55
Service Charts
56
Top Cover and Center Frame
56
Rear Cover, Starboard Cover and Starboard Frame
57
Port Cover and Frame, Front Cover and Frame
58
Rigging Center
59
Cover Removal
60
Cover Installation
62
Frame Removal
64
Starboard, Port, and Front Frame Removal
64
Center Frame Removal
67
Center Frame Installation Installation
71
Frame Installation
71
Front, Port, and Starboard Frame Installation
73
Engine and Control Systems
77
Engine Management Module (EMM)
78
EMM Inputs and Outputs Diagram
79
Barometric Pressure Sensor
80
Circuit Sensor
80
EMM Temperature Sensor
80
Engine Control Systems
80
Internal Sensors
80
Air Temperature Sensor
81
Engine Temperature Sensor
81
Exhaust Pressure Sensor
81
Exhaust Temperature Sensor
81
External Sensors
81
Low Oil Level Switch
82
Oil Level Sensor
82
Crankshaft Position Sensor
83
Dynamic Power Steering
83
Electronic Shift Controller
83
Electronic Throttle Controller
83
Idle Controller
83
Internal EMM Functions
83
Knock Sensor
83
ROM Verification
83
Start Assist Circuit (SAC)
83
Electronic Throttle Controller
84
Engine Monitor and Warning Systems
84
Fault Code Creation and Storage
84
Neutral RPM Limiter
84
RPM Limiter
84
Throttle, Shift and Steering Control Systems
84
Electronic Shift Controller
86
Engine Monitor System
88
Warning System
89
Diagnostic Software Functions
90
EMM Servicing
96
System Analysis
101
Diagnostic Procedures
102
Diagnostic Software Inspections
102
Visual Inspections
102
Operational Inspections
103
Troubleshooting
104
Fuel System Static Tests
105
Ignition System Static Test
105
Static Tests
105
Oil System Static Tests
106
Cylinder Drop Tests
107
Dynamic Tests
108
Fuel Control Adjustment
108
Electrical and Ignition
109
Service Charts
110
Electrical Harness Connections
112
Fuses
115
Ground Circuits
115
Air Temperature Sensor (AT) Test
116
Air Temperature Sensor Circuit Test
116
Sensor and Circuit Tests
116
CPS Circuit Test
117
Crankshaft Position Sensor (CPS) Operation Test
117
Crankshaft Position Sensor (CPS) Resistance Test
117
Engine Temperature Circuit Test
118
Engine Temperature Sensor Test
118
Exhaust Temperature Circuit (EGT) Test
118
Exhaust Temperature Sensor (EGT) Test
118
Knock Sensor Circuit Test
119
Knock Sensor Test
119
Ignition System
120
Required Systems
120
Ignition System Circuit Diagram
121
Ignition System Tests
122
Wiring Inspection
122
Ignition Circuit Tests
123
Ignition Coil Tests
123
Stator Tests
125
Charging System Tests
127
Electric Start Circuit
129
Start Circuit Diagram
129
Start Circuit Operation
130
Electric Starter Tests
131
Starter Voltage Drop Test
131
Starter Voltage Test
131
Tilt/Trim Relay Test
132
Flywheel and Stator Servicing
133
Ignition Coil Servicing
135
Timing Adjustments
136
Timing Pointer
136
Electric Starter Servicing
138
Timing Verification
138
Connector Servicing
139
Fuel System
145
Reed Plate Assembly and Throttle Body
146
Service Charts
146
Fuel Pump and Vapor Separator, Fuel Filter and Fuel Rails ABA & AFA Models
147
Fuel Pump and Vapor Separator, Fuel Filter and Fuel Rails AGA & Newer Models
148
Fuel Injectors
149
Fuel System Flow Diagram (AB, AF Models)
150
Fuel System Flow Diagram (AG & Newer)
151
Fuel System Circuit Diagram
152
Fuel Flow Requirements
153
Fuel System Requirements
153
Permanent Fuel Tanks
153
Portable Fuel Tanks
153
Regulations and Guidelines
153
Fuel Requirements
154
Components
155
Fuel Pump & Vapor Separator Assembly
155
Mechanical Fuel Lift Pump (AGA & Newer)
155
Fuel Filters
158
Fuel Rails
158
Fuel Injectors
159
Fuel System Pressure Tests
160
Fuel System Priming
160
Fuel System Tests
160
Fuel System Electrical Tests
164
Fuel Component Servicing
168
Fuel Filter Service
168
Relieving Fuel System Pressure
168
Mechanical Fuel Lift Pump Service
169
Vapor Separator Service
170
Fuel Rail Service
172
Fuel Injector Service
174
Intake Manifold Service
180
Throttle Valve Service
180
Oiling System
185
Oil Tank Assembly
186
Service Charts
186
Cylinder Oil Pump Assembly
187
Oiling System Circuit Diagram
188
Oil Recirculation Diagram
189
200, 225, 250 HP, 250 H.O., 300 HP Models - Starboard
190
Oil Supply Diagrams
190
200, 225, 250 HP, 250 H.O., 300 HP Models - Rear
191
Checking Oil Level
192
Components
192
Oil Requirements
192
Oil Tank Assembly
192
Optional Remote Oil Tank Kits
192
Recommended Lubricants
192
Crankcase Oil Pump
193
Cylinder Oil Pump
193
Oil Level Sender
193
Cylinder and Crankcase
194
LOW OIL Switch
194
Oil Warning System
194
Break-In Oiling
195
Oil Recirculation System
195
Oil Supply Priming
196
Oil Pump Electrical Tests
198
Oiling System Tests
198
Oil Pump Circuit Tests
200
Oil Pump Resistance Test
201
LOW OIL Switch Circuit Test
202
LOW OIL Switch Test
202
Oil Fittings Flow Test
202
Oil Pump Function Test
202
Oil Level Sender Circuit Test
203
Oil Level Sender Resistance Test
203
Oil Component Servicing
204
Oil Distribution Hoses
204
Oil Tank Servicing
205
Crankcase Oil Pump
206
Cylinder Oil Pump
207
Cooling System
209
Water Flow
210
Water Flow and Hose Routing Diagrams
210
Cooling Hose Routing Diagram - Port
212
Cooling Hose Routing Diagram - Starboard
213
Cooling Hose Routing Diagram - Rear
214
Cooling Hose Routing Diagram - Top
215
Components
216
Exhaust Adapter
216
Pressure Relief Valve
216
Water Pump and Intakes
216
Water Supply Tube
216
Block Venting
217
Cylinder Block / Cylinder Head Cooling
217
Operation
217
Thermostats
217
EMM and Vapor Separator Cooling
218
Engine Temperature Check
218
Idle Operating Temperature Troubleshooting (below Range)
219
Pyrometer Method
219
Software Method
219
Component Servicing
221
Temperature Sensor Servicing
221
Thermostat Servicing
221
Pressure Relief Valve Servicing
222
Evinrude Icon II Remote Control System
223
Components
224
ICON II Remote Control
224
NMEA 2000 Network
225
Outboard EMM
225
Remote Control (Private) Network
225
Shift Actuator
225
Multiple Engine Instancing
226
System Settings and Diagnostics
226
Throttle Valve Assembly
226
Fluid Level Configuration
229
Remote Control Configuration
229
Remote Control Identity
229
Remote Control Faults
230
Remote Control Monitor
230
Remote Control Software
230
ICON II System Fault Detection
231
Powerhead
233
Cylinder Head
234
Service Charts
234
Crankshaft and Pistons
235
Cylinder and Crankcase (Port, Starboard, Front)
236
Cylinder and Crankcase (Bottom, Top, Rear)
237
Cylinder and Crankcase to Exhaust Adapter and Exhaust Housing
238
Compression Testing
239
Powerhead Removal
239
Powerhead Disassembly
244
Systems Removal
244
Crankcase Disassembly
245
Cylinder Head Removal
245
Connecting Rods and Pistons
246
Crankshaft Removal
247
Powerhead Studs
249
Cylinder Block Cleaning
250
Powerhead Inspection
251
Crankshaft Assembly
254
Powerhead Assembly
254
Pistons and Connecting Rods
256
Installing Pistons
257
Cylinder Head Installation
258
Crankshaft and Connecting Rods
259
Deck Cover Installation
259
Crankcase Assembly
262
Final Powerhead Assembly
263
Powerhead Installation
264
Pre-Service Adjustments
264
Powerhead Views
271
Starboard
271
Port - Non-DPS Models
272
Port - DPS Models
273
Rear - 200, 225, 250 HP Models
274
Rear - 250 H.O., 300 HP Models
275
Front - Frame Removed
276
Front - Frame Installed
277
Exhaust Water Valve
278
Water Flow
278
Circuit Tests
279
Dynamic Test
279
Exhaust Water Valve Operation
279
Exhaust Water Valve Tests
279
Static Test
279
Water Valve Resistance Test
280
Exhaust Water Valve Component Service
281
Exhaust Housing & Adapter
283
Exhaust Housing
284
Service Charts
284
Adapter and Muffler
285
Cleaning and Inspection
286
Exhaust Housing Removal
286
Exhaust Housing Service
286
Exhaust Adapter Removal
287
Exhaust Housing Installation
287
Exhaust Adapter Installation
289
Exhaust Water Cooling Fitting
290
Lower Mount Service
291
Upper Mount Service
291
Exhaust Relief Muffler Assembly
292
Stern and Swivel
293
Service Charts
294
Stern & Swivel
294
Spray Plate, Covers and Anode
295
Steering Arm, End Cap and Lower Bracket
296
Stern & Swivel Bracket Attachments
297
DPS Manifold Assembly
298
DPS Pressure Sensors
299
Trim & Tilt Manifold Assembly (Non-DPS Models)
300
ABA Models (DPS-1)
301
AFA & Newer Models (DPS-2)
301
Dynamic Power Steering (DPS)
301
DPS Electrical Circuit Diagram
303
DPS System Tests
304
Steering Ground Circuits
304
Steering Supply Circuits
304
Canbus Circuit
305
Steering Motor Circuits
305
Steering Pressure Sensor Tests
305
Steering Sensor Circuits
305
Steering Position Sensor Service
306
Steering Position Sensor Test
306
DPS Module Installation
307
DPS Module Removal
307
DPS Module Service
307
DPS Software Installation
308
DPS System Calibration
309
DPS Manifold Service
314
Removal
314
Cleaning and Inspection
316
Installation
316
Disassembly
319
Assembly
320
Steering Pressure Sensors
321
Electric Motor
322
Trim & Tilt Manifold Service
323
Trim & Tilt System Service
323
Trim Rod Service
330
Filling the Trim and Tilt System
332
Trim and Tilt Fluid Level
332
Removal
334
Stern & Swivel Bracket
334
Installation
337
Stern Bracket Service
339
Steering Arm, End Cap and Lower Bracket Service
344
Trim Sender Service
344
Gearcase
351
Propeller Hardware
353
Service Charts
353
Water Pump and Gearcase Housing
354
Driveshaft and Shift Actuator
355
Standard Rotation Propeller Shaft
356
Counter Rotation Propeller Shaft
357
Gearcase Type
358
Housing Profile
358
Inspection
359
Propeller Selection
359
Propeller Service
359
Propeller Hardware Installation
360
Gearcase Leak Test
361
Gearcase Removal and Installation
361
Disassembly
365
Water Pump Service
365
Assembly
366
Inspection
366
Shift Rod Adjustment
368
Control Circuit Tests
369
Neutral Circuit
369
Shift Actuator
369
Shift Actuator Ground Circuit
369
Shift Actuator Installation
370
Shift Actuator Removal
370
Shift Actuator Service
370
Shift Actuator Calibration
372
Gearcase Disassembly
373
Pre-Disassembly Inspection
373
Propeller Shaft Bearing Housing and Reverse Gear Removal
374
Pinion Gear and Lower Driveshaft Removal
376
Oil Pump Service
377
Propeller Shaft and Forward Gear Removal
378
Shift Housing Removal
379
Pinion Bearing Installation
380
Pinion Bearing Removal
380
Shifter, Bearing and Seal Servicing
380
Water Intake Screens
380
Propeller Shaft Disassembly
381
Shift Housing Disassembly
382
Shift Housing Assembly
383
Shift Rod Bushing Service
385
Driveshaft Bearing Housing Service
386
Propeller Shaft Bearing Housing Service
387
Driveshaft Shimming
391
Gearcase Assembly
392
Shift Housing, Gear, and Propeller Shaft Installation
392
Water Intake Screens
392
Pinion Gear and Driveshaft Installation
393
Propeller Shaft Bearing Housing and Gear Installation
395
Final Assembly and Adjustment
397
Gearcase Disassembly
397
Pre-Disassembly Inspection
397
Propeller Shaft, Propeller Shaft Bearing Housing and Forward Gear Removal
397
Clutch Shaft and Reverse Gear Removal
399
Pinion Gear Removal and Driveshaft Servicing
399
Shift Housing Disassembly
401
Shift Housing Removal
401
Shifter, Bearing and Seal Servicing
401
Water Intake Screens
401
Shift Housing Assembly
403
Pinion Bearing
405
Propeller Shaft Bearing Housing and Forward Gear
405
Driveshaft Shimming
408
Gearcase Assembly
410
Shift Housing, Gear, and Propeller Shaft Installation
410
Water Intake Screens
410
Pinion Gear and Driveshaft Installation
412
Propeller Shaft, Propeller Shaft Bearing Housing and Gear Installation
412
Final Assembly and Adjustment
414
Safety
415
Marine Products and the Safety of People Who Use Them
417
Outboard Shift Systems and Safety
418
Outboard Speed Control System and Safety
419
Outboard Steering Control System and Safety
420
Outboard Fuel, Electrical System, and Safety
422
Outboard Mounting System and Safety
425
If Weakened, Parts Could Fail Later on the Water, When Not Expected
426
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
427
Outboard Emergency Stop System and Safety
428
Summary
430
Handling Outboards
431
Marine Products and the Safety of People Who Fix Them
431
Handling Lead/Acid Batteries
435
Gasoline - Handle with Care
436
Hazardous Products
437
Safety Awareness Test
438
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