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E90DPLSCB
Evinrude & Johnson E90DPLSCB User Manual
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15
SPECIAL TOOLS
UNIVERSAL TOOLS
1
Small puller jaws P/N 432131
23150
Tilt tube nut wrench P/N 342680
46879
T
emper
ature gun P/N 772018
45240
Large puller jaws P/N 432129
23148
Tilt tube service kit P/N 434523
33249
Fresh water flusher P/N 500542
501
10
Bearing puller jaws P/N 432130
23149
Syringe P/N 346936
50243
Oetiker
â€
pincers, P/N 787145
001081
16
18
Table of Contents
Able of
4
Table of Contents
4
Safety
6
Abbreviations Used in this Manual
8
Introduction
8
List of Abbreviations
8
Units of Measurement
8
Dealer's Responsibility
9
Engine Emissions Information
9
Epa Emission Regulations
9
Manufacturer's Responsibility
9
Owner's Responsibility
9
Model Designation
10
Identifying Model and Serial Numbers
11
Models Covered in this Manual
11
Service Specifications
12
Product Reference and Illustrations
14
Standard Torque Specifications
14
Special Tools 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
22
Shop Aids
23
Notes
26
Table of Contents
27
Boat Rigging
28
Remote Controls
28
Battery Installation
29
Battery Switches and Multiple Batteries
30
Installation and Predelivery
30
Battery and Switch Wiring Diagrams
32
Fuel System Requirements
34
Fuel Filters
35
Cable and Hose Installation
36
Battery Cables
37
Outboard Installation
40
Hull Preparation
40
Transom Measuring and Drilling
42
Lifting the Outboard
45
Steering Systems
45
Outboard Mounting
47
Outboard Rigging
48
Cable, Hose, and Wire Routing
48
Control Cable Adjustments
48
Electrical Harness Connections
50
Water Pressure Gauge
50
Canbus Connections
51
Fuel and Oil Priming
53
Fuel Requirements
53
Fuel System Priming
54
Oil Requirements
54
Oil Injection Rate
55
Break-In Oiling
56
Oil Supply Priming
56
Before Start-Up
57
Oil Level
57
Running Checks
58
Engine Monitoring System
58
Fuel System
58
Emergency Stop / Key Switch
58
Remote Control Operation
58
Start-In-Gear Prevention
58
Tachometer Pulse Setting
58
Water Pump Overboard Indicator
59
Operating Temperature
59
Propellers
60
Propeller Selection
60
Propeller Hardware Installation
61
Final Adjustments
62
Tilt Limit Switch Adjustment
62
Trim Sending Unit Adjustment
63
Trim Tab Adjustment
64
Dual-Outboard Alignment
65
Notes
66
Maintenance Maintenance
67
Inspection and Maintenance Schedule
68
Anti-Corrosion Protection
69
Sacrificial Anodes
69
Testing Procedure - Continuity
69
Metallic Component Protection
69
Exterior Finishes
69
Cooling System
70
Flushing
70
Maintenance
70
Water Intake Screens
71
Additional Maintenance
71
Lubrication
71
Steering System
71
Swivel Bracket and Trailering Bracket
72
Tilt Tube
72
Throttle and Shift Linkage
72
Propeller Shaft
73
Gearcase Lubricant
73
Trim and Tilt
75
Battery and Battery Connections
76
Fuel and Oil Systems
76
Fuel Filter
76
Oil Filters and Oil Reservoir
76
Air Silencer
77
Hoses and Connections
77
Spark Plugs
78
Removal
78
Indexing
78
Storage
79
Fuel System Treatment
79
Internal Engine Treatment
79
Additional Recommendations
80
Pre-Season Service
80
Outboard Mounting Bolts
80
Gearcase Lubricant
80
Battery(S)
80
Power Trim and Tilt
80
Operational Checks
80
Submerged Engines
81
Engine Dropped Overboard (Not Running)
81
Engine Dropped Overboard (Running)
81
Engine Dropped Overboard (in Salt Water)
81
Prolonged Submersion (Fresh or Salt Water)
81
Notes
82
Engine Cover Service
86
Table of Contents
87
Description
88
Emm Functions
88
Emm Connections
88
Led Indicators
88
Emm Inputs and Outputs Diagram
89
Internal Sensors
90
Emm Temperature Sensor
90
55 V Circuit Sensor
90
Engine Management Module (Emm)
90
Barometric Pressure Sensor
91
External Sensors
91
Air Temperature Sensor
91
Engine Temperature Sensor
92
Low Oil Switch
92
Throttle Position Sensor
92
Crankshaft Position Sensor
93
Neutral Switch
93
Internal Emm Functions
94
Engine Monitoring System
95
Engine Running
95
Service Mode
95
Shutdown Mode
96
Warning System
96
Diagnostic Software Functions
97
Communication
97
Static Information
97
Dynamic Information
98
Stored Service Codes (Faults)
98
Hard Faults
98
Persistent Faults
98
Static Tests
98
Dynamic Tests
99
Oil Control Settings
100
Tiller/Remote Programming
100
Ignition Timing
101
Tps Calibration
101
Idle Speed Control
101
Fuel Injector Servicing
102
Reports
102
Software Replacement
103
Emm Transfer
103
Emm Servicing
104
System Analysis System Analysis
105
Diagnostic Procedures
106
Visual Inspections
106
Operational Inspections
106
Troubleshooting
107
Dynamic Tests
108
Cylinder Drop Tests
108
Fuel Control Adjustment
108
Inductive Amp Meter Test
108
System Analysis
108
Emm Led Indicators
109
Key on
109
Starting
109
Running
110
Ignition Output Tests
111
Ignition System Requirements
111
Wiring Inspection
111
Crankshaft Position Sensor (Cps) Test
112
System Voltage Test
112
Static Ignition Test
113
Running Ignition Tests
114
Ignition Control Circuit Tests
115
Ignition Coil Tests
115
Capacitor Test
115
Fuel Delivery Tests
116
Fuel Pump Static Test
116
Fuel Injector Static Test
116
Running Fuel System Tests
117
Notes
118
Electrical and Ignition Electrical and Ignition
119
Electrical and Ignition
120
Service Chart
120
Dash Connections, Instrument Harness
122
Electrical and Ignition
122
Electrical Harness Connections
123
Fuse
125
Ground Circuits
125
Sensor Tests
126
Crankshaft Position Sensor (Cps) Test
126
Throttle Position Sensor (Tps) Test
126
Engine Temperature Sensor Test
127
Air Temperature Sensor (At) Test
127
Stator Tests
128
Charging System Tests
129
V Alternator Circuit
130
Electric Start Circuit
131
Electric Start Tests
133
No Load Current Draw Test
134
Remote Control Switch Tests
135
Key Switch Test
135
Neutral Start Circuit Test
135
Neutral Start Switch Test
136
Emergency Stop Switch Test
136
Tilt/Trim Relay Test
137
Systemcheck Circuit Tests
138
Gauge Self-Test Check
138
Check Engine Circuit Test
139
Water Temp/ Hot Circuit Test
139
Low Oil Circuit Test
140
No Oil Circuit
140
Tachometer Circuit Tests
140
Flywheel and Stator Servicing
141
Flywheel Removal
141
Stator Service
143
Flywheel Installation
143
Timing Adjustments
144
Timing Pointer
144
Timing Verification
145
Tps Calibration
145
Electric Starter Servicing
146
Starter Removal
146
Starter Disassembly
146
Starter Cleaning and Inspection
147
Starter Assembly
148
Starter Installation
149
Connector Servicing
150
Table of Contents
155
Service Chart
156
Fuel System Hose Routing
158
Fuel System Circuit Diagram
159
Components
160
Fuel Lift Pump
160
Fuel Filter
160
Vapor Separator
160
Fuel Circulation Pump
161
Fuel Manifolds
162
Fuel Injectors
162
Fuel System Tests
163
Fuel System Pressure Test
163
Pressure Regulator Test
164
Vapor Separator Vent Check
164
Fuel Injector Pressure Test
164
Fuel Injector Resistance Test
165
Circulation Pump Resistance Test
165
Lift Pump Pressure Test
165
Lift Pump Vacuum Test
166
Lift Pump Diaphragm Test
167
Anti-Siphon Valve Test
167
Fuel Component Servicing
168
Relieving Fuel System Pressure
168
Fuel Filter Service
169
Fuel Lift Pump Service
169
Vapor Separator Service
170
Fuel Manifold Service
170
Fuel Injector Service
171
Intake Manifold Service
174
Oiling System Oiling System
177
Service Chart
178
Oiling System
178
Oil Supply Diagrams
179
Oil Recirculation Diagram
180
Oiling System
180
Oiling System Circuit Diagram
181
Components
182
Oil Tank Assembly
182
Oil Injection Pump
182
Electrical Circuit (55 V)
182
Low Oil Warning
183
No Oil Warning
183
Cylinder and Crankcase
183
Oil Recirculation System
184
Oil Control Settings
184
Oil Priming
184
Oiling Rates
184
Break-In Oiling
184
Oiling System Tests
185
Oil Injection Pump Static Test
185
Oil Injection Pump Voltage Test
185
Oil Injection Pump Circuit Resistance Test
186
Oil Injection Pump Function Test
186
Oil Injection Fittings Flow Test
187
Low Oil Sending Unit Test
187
Oil Component Servicing
188
Oil Distribution Hoses
188
Oil Tank Assembly
189
Notes
190
Cooling System Cooling System
191
Hose Routing and Water Flow Diagram
192
Components
193
Water Pump and Intakes
193
Water Supply Tube
193
Adapter/Inner Exhaust Housing
193
Pressure Relief Valve
194
Thermostat
194
Block Venting
194
Water Pressure Connection
194
Cooling System
194
Operation
195
Cylinder Block / Cylinder Head Cooling
195
Emm and Vapor Separator Cooling
195
Engine Temperature Check
196
Software Method
196
Pyrometer Method
196
Idle Operating Temperature Troubleshooting (below Range)
197
Thermostat Inspection
197
Thermostat Servicing
198
Disassembly
198
Inspection
198
Assembly
198
Pressure Relief Valve Servicing
199
Disassembly
199
Inspection
199
Assembly
199
Notes
200
Powerhead Powerhead
201
Service Chart
202
Powerhead Removal
204
Powerhead Disassembly
206
General
206
Throttle Linkage Removal
206
Shift Linkage Removal
206
Crankcase Disassembly
207
Cylinder Head Removal
208
Connecting Rods and Pistons
208
Crankshaft Removal
209
Cylinder Block Cleaning
212
Powerhead Inspection
213
Cylinder Head
213
Crankshaft
213
Cylinder Bore
213
Pistons
214
Piston Rings
214
Bearings
215
Powerhead Assembly
215
Crankshaft Assembly
215
Pistons and Connecting Rods
217
Cylinder Head Installation
219
Crankshaft and Connecting Rod Installation
220
Crankcase Assembly
223
Shift Linkage Installation
225
Throttle Linkage Installation
225
Final Powerhead Assembly
226
Upper Mount Servicing
227
Removal
227
Installation
227
Powerhead Installation
228
Powerhead Mounting
228
Shift Linkage Adjustment
230
Powerhead Views
231
Port Short Block
231
Starboard Short Block
231
Port Dressed Powerhead
232
Starboard Dressed Powerhead
232
Front
233
Rear
234
Top
235
Notes
236
Midsection Midsection
237
Service Chart
238
Tilt Tube
240
Removal
240
Midsection
240
Installation
241
10 Cooling System
240
11 Powerhead
240
Exhaust Housing
242
Exhaust Housing Removal
242
Exhaust Housing Disassembly
243
Cleaning and Inspection
244
Exhaust Housing Assembly
244
Exhaust Housing Installation
247
Stern Bracket
248
Stern Bracket Removal
248
Stern Bracket Disassembly
248
Stern Bracket Assembly
250
Swivel Bracket Disassembly (Manual Tilt)
253
Swivel Bracket Assembly (Manual Tilt)
255
Notes
258
Gearcase Gearcase
259
Service Chart
260
Gearcase Leak Test
262
Propeller Service
262
Inspection
262
Gearcase Types
262
Gearcase Removal and Installation
263
Gearcase Removal
263
Gearcase Installation
264
Water Pump
265
Disassembly
265
Inspection
265
Assembly
266
Shift Rod Adjustment
268
Gearcase Disassembly
269
Pre-Disassembly Inspection
269
Propeller Shaft Bearing Housing Removal
270
Pinion Gear and Driveshaft Removal
270
Driveshaft Service
272
Shift Housing, Gear and Propeller Shaft Removal
273
Water Intake Screens
273
Gearcase Housing Inspection
273
Internal Gearcase Service
274
Pinion Bearing Removal
274
Pinion Bearing Installation
274
Shift Housing Disassembly
275
Shift Housing Assembly
277
Driveshaft Bearing Housing Service
279
Propeller Shaft Bearing Housing Service
280
Driveshaft Shimming
282
Gearcase Assembly
283
Water Intake Screens
283
Shift Housing, Gear, and Propeller Shaft Installation
283
Shift Rod Housing Installation
284
Pinion Gear and Driveshaft Installation
285
Propeller Shaft Bearing Housing and Gear Installation
286
Notes
288
Gearcase Notes Notes
289
System Description
290
Manual Adjustment
290
Trailering Bracket and Tilt Support
290
Routine Inspections
291
General
291
Reservoir Fluid
291
Manual Release Valve
291
Stern Brackets
291
Troubleshooting
291
Electrical Circuit Tests
292
Relay Testing
292
Trim and Tilt Motor Current Draw Tests
292
Trim and Tilt Motor no Load Test
293
Trim Gauge Test
293
Trim Sender Test
294
Servicing
294
Removal
294
Disassembly
296
Assembly
297
Installation
298
Adjustments
299
Notes
300
Safety Safety
301
Marine Products and the Safety of People Who Use Them
303
Outboard Shift Systems and Safety
304
Outboard Speed Control System and Safety
305
Outboard Steering Control System and Safety
306
Outboard Fuel, Electrical System, and Safety
308
Outboard Mounting System and Safety
311
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
313
Outboard Emergency Stop System and Safety
314
Summing up
316
Marine Products and the Safety of People Who Fix Them
317
Handling Outboards
317
Handling Lead/Acid Batteries
321
Gasoline - Handle with Care
322
Hazardous Products
323
Safety Awareness Test
324
Trouble Check Chart
333
4
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Evinrude & Johnson E90DPLSCB Specifications
General
Brand
Evinrude & Johnson
Model
E90DPLSCB
Category
Engine
Language
English
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