OIL INJECTION

FUEL SYSTEM
Section 3C – Oil Injection
Table of Contents
Oil System Operation . . . . . . . . . . . . . . . . . . . . 3C-1 Priming the Oil Pump . . . . . . . . . . . . . . . . . 3C-12
Oil Pump Output . . . . . . . . . . . . . . . . . . . . . 3C-1 Priming Procedure – Method 1 . . . . . . . . . 3C-13
Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-2 Remote Oil Hose Connections . . . . . . . . . 3C-14
Oil Hose Check Valve Installation on
1998 Model 135/150 DFI Outboards
Filling the Oil Tanks . . . . . . . . . . . . . . . . . . .
Purging Air From the Engine Oil Reservoir
3C-14
3
SN 0G886266 and Below . . . . . . . . . . . . . .
Oil Injection Hose Installation . . . . . . . . . .
3C-3
3C-9
and Remote Oil Hose . . . . . . . . . . . . . . . . .
Oil Warning Systems . . . . . . . . . . . . . . . . . .
3C-15
3C-15
C
Oil Pump Removal and Installation . . . . . 3C-10 Oil System Troubleshooting . . . . . . . . . . . . . . 3C-16
Engine Oil Reservoir Removal Low Oil Warning System is Activated . . . 3C-16
and Installation . . . . . . . . . . . . . . . . . . . . . . . 3C-11

Oil System Operation

Oil in this engine is not mixed with the fuel before entering the combustion chamber. Oil
is stored inside the remote oil tank in the boat. Crankcase pressure forces oil from the
remote oil tank into the engine oil reservoir. The engine oil reservoir feeds oil to the oil
pump. The oil pump is ECM driven and controls oil distribution to the crankcase and air
compressor. The oil pump has seven oil discharge ports. Six of the oil discharge ports in-
ject oil into the crankcase through hoses, one hose for each cylinder. The last oil discharge
port discharges oil into the air compressor for lubrication. Unused oil from the air compres-
sor returns to the plenum and is ingested through the crankcase.
The ECM is programmed to automatically increase the oil supply to the engine during the
initial engine break-in period. The oil ratio is doubled during the first 120 minutes of opera-
tion whenever engine speed exceeds 2500 RPM; below 2500 RPM the oil pump provides
oil at the normal ratio. After the engine break-in period, the oil ratio will return to normal
– 300 - 400:1 at idle to 60:1 at WOT.
NOTE: On some light boat applications after the break-in is completed and the engine is
being run at cruising speed – between 4000 and 5000 RPM – the fuel to oil ratio may be
as high as 28:1. This results from a reduced throttle opening with a corresponding reduc-
tion in fuel consumption.
Oil Pump Output
Using the DDT to activate auto prime, the oil pump should discharge 110 ml (cc) ± 8 ml
(cc) during the auto prime time period.
To check the oil pump output:
• Verify the onboard oil reservoir is full.
• Release any pressure (loosen cap) from the remote oil tank in the boat.
• With engine not running, use the DDT to activate the auto prime.
• Using a ml or cc graduated container, record the amount of oil needed to refill the on-
board oil reservoir.
• Retighten cap on the remote oil tank in the boat.

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OIL INJECTION

Oil System
f
h
g

b
e

c
a

a - Remote Oil Tank

b - Engine Oil Reservoir
c - Oil Supply Hose to the Oil Pump
d - Oil Pump
e - Oil Supply Hoses to the Cylinders (6)
f - Oil Supply Hose to the Air Compressor
g - Air Compressor
h - Check Valve
i - Oil Return Hose from the Air Compressor

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 OIL INJECTION

Oil Hose Check Valve Installation on 1998 Model 135/150 DFI Outboards
SN 0G886266 and Below
To prevent possible momentary oil starvation in the oil pump delivery hoses, it is recom-
mended that check valve kit 21-858945A2 be installed as follows:
NOTE: Refer to Service Bulletin 98-23.
1. Remove flywheel cover. Pull out vent hose.

a - Vent Hose

2. Remove 4 bolts securing bottom cowl halves and remove bottom cowling.

52352

a
55932 55970 a
a - Bolts

3. Remove throttle cable from throttle arm.

a - Throttle Cable

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OIL INJECTION

4. Remove 3 bolts securing oil reservoir and lay reservoir off to one side.

a
b

a - Bolts
b - Oil Reservoir

5. Remove throttle link arm and bolt securing throttle arm. Remove throttle arm.

a - Throttle Link Arm

b - Bolt
c - Throttle Arm

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 OIL INJECTION

6. Remove alternator/air compressor belt.

7. Remove aft alternator bolt and pivot alternator forward.

a - Alternator/Air Compressor Belt

b - Belt Tensioner (rotate counterclockwise)
c - Aft Alternator Bolt
d - Alternator (rotate forward)

NOTE: It is recommended that a razor knife be used to make a small slit in the oil hoses
to aid in removal. Removing hoses without cutting them may result in the breakage of the
oil fitting. Trim cut portion off of oil hose before reinstalling hose.
8. Remove oil hoses from fittings on #2, #4, and #6 cylinders.

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OIL INJECTION

NOTE: All check valve/hose assemblies for cylinders 2, 4, 6 are brass colored and have
1.250 (31.75 mm) long hoses attached to check valve.
IMPORTANT: Due to the close proximity of the #2 cylinder oil hose to the flywheel,
it will be necessary to trim the length of the #2 oil hose to provide adequate clear-
ance between the oil hose and the flywheel when the check valve assembly is
installed.
9. Trim off #2 cylinder oil hose to an appropriate length (to provide clearance between
hose and flywheel) and install new check valve/hose assembly. Secure hose connec-
tions with sta-straps.
10. Install new check valve/hose assemblies on cylinders #4 and #6. Secure all hose con-
nections with sta-straps.

d a

d b

d
c

57410

a - #2 Cylinder Oil Hose [Trim hose length as required]

b - #4 Check Valve/Hose Assembly
c - #6 Check Valve/Hose Assembly
d - Sta-straps

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11. Reinstall throttle control arm. Connect throttle link to throttle cam. Torque bolt to 20
lb. ft. (27 Nm).
12. Reinstall oil reservoir. Torque bolts to 170 lb. in. (19 Nm).
13. Reinstall alternator. Torque bolt to 40 lb. ft. (54 Nm).

57409

a - Torque Bolt to 20 lb. ft. (27 Nm)

b - Torque Bolts to 170 lb. in. (19 Nm)
c - Torque bolt to 40 lb. ft. (54 Nm)

14. Reinstall alternator/air compressor belt.

15. Remove Electronic Control Module (ECM) (lay off to one side).
16. Remove solenoid/trim relay plate (lay off to one side).
17. Remove starter motor (lay off to one side).
NOTE: All check valve/hose assemblies for cylinders 1, 3, 5 have a BLUE stripe/band and
a 3.125 in. (79.37 mm) long hose attached to the check valve.

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OIL INJECTION

18. Install new check valve/hose assemblies on cylinders #1, #3 and #5. Secure all hose
connections with sta-straps.
a

57411

a - #1 Cylinder Check Valve/Hose Assembly

b - #3 Cylinder Check Valve/Hose Assembly
c - #5 Cylinder Check Valve/Hose Assembly

19. Reinstall starter motor. Torque bolts to 17.5 lb ft. (23.5 Nm).
20. Reinstall starter solenoid/trim relay plate. Torque bolts to 150 lb. in. (17 Nm).
21. Reinstall ECM. Torque bolts to 70 lb. in. (8 Nm).

c c
b
b

57412

a - Torque bolts to 17.5 lb ft. (23.5 Nm)

b - Torque bolts to 150 lb. in. (17 Nm)
c - Torque bolts to 70 lb. in. (8 Nm)

22. Reinstall bottom cowling.

23. Reinstall flywheel cover.

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 OIL INJECTION

Oil Injection Hose Installation

Install the correct inside diameter and length of hose between oil pump and fittings on the
engine (see chart below). Cylinders #1, #3, #5 only have a BLUE stripe/band.
Fasten hoses on both ends with sta-straps.
a

c
Cyl #1
d
Cyl #2

3 d
Cyl #3 5
Cyl #4

d
2 d d
Cyl #5 6
Cyl #6

Cyl a
#5
1 d
Cyl b 7
Cyl #1
#3 Cyl
#2
Cyl
Cyl #4
#6

a - Air Compressor c - Fasten Hose Ends with Sta-Straps

b - Oil Pump d - Check Valves
e - Check Valve (oil return)

Cyl. #1 0.078 in. (1.98 mm) I.D. Check Valve Oil Hose Sizes
with 3.125 in. (79.4 mm) length Hose Hose Inside Diameter Length ± 0.20
Cyl. #3 0.078 in. (1.98 mm) I.D. Check Valve ± .01 (0.25mm) (5.1 mm)
with 3.125 in. (79.4 mm) length Hose
Cyl. #5 0.078 in. (1.98 mm) I.D. Check Valve
with 3.125 in. (79.4 mm) length Hose
1 0.125 (3.2 mm) 16 in. (406 mm)
Cyl. #2 0.063 in. (1.60 mm) I.D. Check Valve
with 1.250 in. (31.7 mm) length Hose 2 0.125 (3.2 mm) 20 in. (508 mm)
Cyl. #4 0.063 in. (1.60 mm) I.D. Check Valve 3 0.125 (3.2 mm) 16 in. (406 mm)
with 1.250 in. (31.7 mm) length Hose 4 0.092 (2.3 mm) 28 in. (711 mm)
Cyl. #6 0.063 in. (1.60 mm) I.D. Check Valve 5 0.092 (2.3 mm) 24 in. (610 mm)
with 1.250 in. (31.7 mm) length Hose
6 0.092 (2.3 mm) 24 in. (610 mm)
Note All check valve I.D. measurements
given are ± 0.002 in. (0.050 mm) 7 0.092 (2.3 mm) 24 in. (610 mm)

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OIL INJECTION

Oil Pump Removal and Installation

REMOVAL
1. Disconnect the wiring harness from the pump.
2. Disconnect the oil hoses.
3. Remove three bolts and remove pump.

a c
b
e
h f g

a - Oil Pump
b - Gasket
c - Bracket
d - Bushing (3)
e - Rubber Grommet (3) – Insert into Hole
f - Washer (3)
g - Bolt (3) – Torque to 16 lb. ft. (21.5 Nm)
h - Sta-Straps – Fasten All Hose Ends

INSTALLATION
1. Install pump as shown.
2. Reconnect the oil hoses. Refer to Oil Injection Hose Installation for correct location.
Fasten hoses to pump fittings with sta-straps.
3. Connect the wiring harness.
NOTE: Replacement oil pump may have 2 pin electrical connection vs. 4 pin with original
oil pump. The 2 pin connection will still function with the existing wire harness.
4. Refill the oil system. Refer to Priming the Oil Pump.

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Engine Oil Reservoir Removal and Installation

REMOVAL
1. Disconnect the oil hoses. Plug the hoses to prevent spillage.
2. Disconnect the LIGHT BLUE wire leads.
3. Remove three bolts securing oil tank and fuel cooler to powerhead and remove tank.

f
e
g
d
c

a
j

b
h
d g e g
i

a - Oil Reservoir
b - Fuel Cooler (Design 1)
c - Bolt (1) – Torque to 170 lb. in. (19 Nm)
d - Washer (3)
e - Rubber Grommet (3) – Insert into Holes
f - Low Oil Switch
g - Bushing (3)
h - Grommet (2) – Insert into Hole
i - Bolt (2) – Torque to 170 lb. in. (19 Nm)
j - Sta-Straps – Fasten All Hose Ends
k - Fuel Cooler (Design 2)

INSTALLATION
1. Install oil reservoir as shown.
2. Fasten the oil hoses with sta-straps.
3. Connect the LIGHT BLUE wire leads.
4. Refill the oil system. Refer to Priming the Oil Pump.

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OIL INJECTION

Priming the Oil Pump

Priming the oil pump (filling pump and hoses) is required on new or rebuild engines and
any time maintenance is performed on the oiling system.
There are three methods for priming the oil pump:
METHOD 1 – SHIFT SWITCH ACTIVATION PRIME
This method does three things:
a. Fills the oil pump, oil supply hose feeding pump and oil hoses going to the crank-
case and air compressor.
b. Activates break-in oil ratio.
c. Initiates a new 120 minute engine break-in cycle.
Refer to priming procedure following.
METHOD 2 – (DDT) DIGITAL DIAGNOSTIC TERMINAL – RESET BREAK-IN
This method is the same as Method 1, except the run history and fault history are erased
from the ECM.
Refer to procedure in the Technician Reference Manual provided with the Digital Diagnos-
tic Software Cartridge Part. No. 91-822608-4 or -5.
METHOD 3 – (DDT) DIGITAL DIAGNOSTIC TERMINAL – OIL PUMP PRIME
This method fills the oil pump, oil supply hose feeding pump, and oil hoses going to the
crankcase and air compressor.
Refer to procedure in the Technician Reference Manual provided with the Digital Diagnos-
tic Software Cartridge Part. No. 91-822608-4 or -5.

Conditions Requiring Priming the Oil Pump

Condition Priming Procedure
New engine Use Method 1 or 2
Rebuilt Powerhead Use Method 1 or 2
New Powerhead Use Method 1 or 2
Oil system ran out of oil Use Method 3
Oil drained from oil supply hose feeding pump Use Method 3
Oil pump removed Use Method 3
Oil injection hoses drained Use Method 3

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Priming Procedure – Method 1

METHOD 1 – SHIFT SWITCH ACTIVATION PRIME PROCEDURE
Before starting engine for the first time, prime the oil pump. Priming will remove any
air that may be in the pump, oil supply hose, or internal passages.

b
a - Oil Injection Pump
b - Oil Supply Hose

CAUTION
To prevent damage to the fuel pumps, fill the engine fuel system with fuel. Other-
wise the fuel pumps will run without fuel during the priming process.

Prime the oil injection pump as follows:

1. Fill the engine fuel system with fuel. Connect fuel hose and squeeze primer bulb until
it feels firm.
2. Turn the ignition key switch to the “ON” position.
3. Within the first 10 seconds after the key switch has been turned on, move the remote
control handle from neutral into forward gear 3 to 5 times. This will automatically start
the priming process.
N
F

NOTE: It may take a few minutes for the pump to complete the priming process.

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OIL INJECTION

Remote Oil Hose Connections

CONNECTING OIL HOSE WITH BLUE STRIPE
1. Remove shipping cap from fitting and connect oil hose (a). Fasten hose with sta-strap.

a - Oil Hose with Blue Stripe

CONNECTING OIL HOSE WITHOUT BLUE STRIPE

1. Remove shipping cap from fitting and connect hose (a). Fasten hose with sta-strap.

a
a - Oil Hose Without Blue Stripe

Filling the Oil Tanks

1. Fill remote oil tank with the recommended oil listed in the Operation and Maintenance
Manual. Tighten fill cap.
2. Remove cap and fill engine oil tank with oil. Reinstall the fill cap.
3. Remove air from remote oil hose. Refer to Purging Air from the Engine Oil Reservoir
and Remote Oil Hose.
c
a
b

a - Fill Cap
b - Engine Oil Reservoir
c - Fill Cap

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 OIL INJECTION

Purging Air From the Engine Oil Reservoir and Remote Oil Hose
NOTE: Before starting engine, make sure the oil pump has been primed.
1. Start the engine. Run the engine until all the air has been vented out of the reservoir
and oil starts to flow out of the reservoir. Re-tighten fill cap.
a

a - Fill Cap

Oil Warning Systems

LOW OIL LEVEL
NOTE: The low oil condition must exist for a minimum of 15 seconds before horn or light
is activated.
The system is activated when the oil in the engine mounted oil reservoir tank drops below
22 fl. oz. (175 ml). There is still an oil reserve remaining for 30 minutes of full speed opera-
tion.
NOTE: The engine mounted oil reservoir (located beneath the top cowl) along with the
remote oil tank will have to be refilled (refer to Filling the Oil tanks).
The warning system works as follows:
The OIL light will come on and the warning horn sounds a series of four short tones. If you
continue to operate the outboard, the light will stay on and the horn will sound four short
tones every two minutes. The engine has to be shut off to reset the warning system.

OIL PUMP NOT FUNCTIONING ELECTRICALLY

The system is activated if the oil pump stops functioning electrically. No lubricating oil is
being supplied to the engine. Stop the engine as soon as possible. Continuing to operate
the engine can result in severe engine damage.
The warning system works as follows:
The OIL light and CHECK ENGINE light will come on and the warning horn will begin
sounding. The warning system will automatically reduce and limit the engine speed to
3000 RPM.
The engine has to be shut off to reset the warning system.

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OIL INJECTION

Oil System Troubleshooting

Low Oil Warning System is Activated
Problem Problem Problem Problem
Low oil level in en- Oil level is not low Oil leaks out of
Low oil level in engine
gine oil reservoir and in either tank exhaust
oil reservoir but not low
also remote oil tank or #6 cylinder
in remote oil tank
Note: Oil level in engine Disconnect BLUE
oil reservoir should be wires going to the
Refill both oil tanks. Pulse hose and
up to the fill cap low oil float switch in
Purge air from en- oil supply hose
the engine oil reser-
gine oil tank. Refer are reversed
voir. Check switch
to procedure
for continuity
Boat oil tank is
Air was never purged from Purge air from engine oil tank. mounted higher
engine oil tank Refer to procedure than pulse hose
fitting on engine
and oil tank is
Fill cap is leaking air on re- Caps on remote tank must be over-filled
mote tank sealed and installed tight

Remote oil hoses blocked or Check hoses for a kink or

punctured leakage
No Continuity

Restricted oil outlet filter in re- Remove filter and clean

mote oil tank Check continuity with engine
running and electrical system
under load. Refer to Service
Bulletin 98-3
Air leak in upper portion on Replace tube
the oil pickup tube
Continuity
Replace oil reservoir
Faulty pressure check valve. Replace check valve
Located in engine at end of
(BLACK without BLUE stripe)
remote oil hose

No Continuity
Check for short between
Continuity BLUE wire in engine harness
Remove screw and pull out and gorund
the oil float switch from the
tank. Check switch again for
continuity

Continuity No Continuity
Oil Float switch is faulty. Re- Float in oil tank is faulty. Re-
place switch place oil tank

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