2001 Ficht 150 Fuel out exhaust.

[dkevinrude]

My 2001 Evinrude 150,

Prior to the EMM Failing with codes 81,82,83,84,85,86, we noticed fuel behind the engine.
Failure of the components happened when the lower thermostat housing (under cylinder #5) corroded spraying salt water on the lower coil creating a arc between the coil wire and spark plug wire.

Started engine testerday with a DFI rebuild emm, new thermostat housing, hoses, dual coil and plug wire. Same thing with unburned fuel coming out the exhaust.

#5 cylinder is not firing, coil wire back to the emm duetch connector ohm tested fine. #3 is firing so the dual coil ground is OK

The tech is scratching is head,
Has this happened to other 150? We were unable to find resolve in the shop manual.

[SEAHORSE]

Remove the coil and clean the ground straps first. That dual coil is actually 2 separate coils in one container. A quick check is to swap #3 and #5 coil wires.

Is number 5 not firing due to no spark or no injection? You can use a timing light to verify spark and voltage pulses to he injector. Take a compression test also.

To cut down on the thermostat housing corrosion, attach a wire from the cover bolt to the engine block so everything is bonded together and that will eliminate the galvanic corrosion.

[dkevinrude]

Thanks Seahorse

No spark with timing light, a new plug was just wet with fuel, injector is injecting fuel.
#3 cylinder same dual coil is firing, ground OK, we installed a second new dual coil and even swapped plug wires. #3 would fire in all instances.
#5 did not, cylinder wet with fuel?

Puzzled,

[SEAHORSE]

Do a pressure test on the injector to see if it leaks through the pintle.

Does the injector click when doing the static test?

Has anyone checked the coil primary voltage with a DVA meter both with the motor running and by static testing using the laptop?

[dkevinrude]

Yes, the injector #5 clicks.

With the key on and lap top connected, which would mean the fuel rail is pressurized, with the spark plug out we used a q-tip to see if the injector was leaking, it wetted during the lap top pulse , and subsequent q-tips dried.

No indication of spark with a timing light.

Could this be the stator component for the #5 cylinder failed as the coil sparked between the coil wire & the plug wire causing the emm to fail with the codes of the 8 series?

[SEAHORSE]

The EMM "fires" the coils individually. A bad EMM could be why #5 isn't firing, that is why you have to determine the DVA voltage at the coil primary. Does the spark jump a 7/16" gap using a spark checker?

Static testing an injector with the laptop does not "fire" it completely. It take 40 volts, not 12 volts to test one. You still have to do the pressure test per the manual to make certain there is no leakage from the injector to foul the plug. Also using a pressure gauge on the fuel rail, see if the pressure drops significantly when the key is turned off, or if it holds close to its running pressure.

What was the compression reading on #5?

[SEAHORSE]

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by dkevinrude &raquo;</TD></TR><TR><TD CLASS="quote">My 2001 Evinrude 150,

....Failure of the components happened when the lower thermostat housing (under cylinder #5) corroded spraying salt water on the lower coil creating a arc between the coil wire and spark plug wire.
</TD></TR></TABLE>


The cylinder by the lower thermostat is #6, not #5. I missed that the first time I read your post.l

[dkevinrude]

Thanks Seahorse
The cylinder is then #6, facing the rear of engine lower left cylinder.
Compression was tested prior to starting any repairs.

#6 was just below 100PSI, remaining cylinders were in the 103 to 105 PSI range.
297 hours on the engine.