Service Manual 5007213_Evinrude E-TEC 115-200 HP Engine Management Module [Emm Diagnostics 2]

The EMM has LED indicators located next to the electrical connectors that provide information related to various electrical circuits.

IMPORTANT: LED 1 is toward the rear of the outboard (Closest to EMM J2 connector).

1. LED indicators

Starting Mode

“Starting mode” occurs from EMM power ON until outboard is running for 2 seconds.

LED 1 – Stator signal 30 V or higher, “CHARGING OKAY.” For NO LIGHT, investigate S.A.C. circuit operation.

LED 2 – Crankshaft position sensor output, EMM powered (ON), “CRANK POSITION OKAY.” For NO LIGHT, investigate possible fault code 16.

LED 3 – Sensor circuits (5 V), “SENSORS OKAY.” For NO LIGHT, investigate possible fault codes: 12, 13, 24, 16, 41, 42, 44, 45, 46, 47, 48, 49, 67, 68, 69.

For FLASHING LIGHT ON, investigate code 57 (High RPM with low TPS setting)

LED 4 – Lanyard/Stop circuit not grounded, “LANYARD/STOP OKAY.”

For NO LIGHT, repair grounded stop circuit.

For FLASHING LIGHT ON, investigate possible fault code 29 (engine shutdown, EMM overheat), code 31 (engine shutdown, engine overheat) or code 33 (engine shutdown, excessive no oil condition).

Running Mode

LED 1 – Low charging output, “CHARGING FAULT.” For LIGHT ON, investigate possible fault codes:

• Code 17 – system voltage (55 V) below range

• Code 18 – system voltage (55 V) above range

• Code 26 – low battery (12 V) voltage

• Code 27 – high battery (12 V) voltage

• Code 77 – S.A.C. overcurrent fault

LED 2 – Damaged injector circuit, ignition primary circuit, or fuel pump circuit, “INJECTOR/IGNITION FAULT.” For LIGHT ON, investigate possible fault codes:

• Code 51 – cylinder no. 1 injector circuit open

• Code 52 – cylinder no. 2 injector circuit open

• Code 53 – cylinder no. 3 injector circuit open

• Code 54 – cylinder no. 4 injector circuit open

• Code 55 – cylinder no. 5 injector circuit open

• Code 56 – cylinder no. 6 injector circuit open

• Code 61 – cylinder no. 1 injector circuit short

• Code 62 – cylinder no. 2 injector circuit short

• Code 63 – cylinder no. 3 injector circuit short

• Code 64 – cylinder no. 4 injector circuit short

• Code 65 – cylinder no. 5 injector circuit short

• Code 66 – cylinder no. 6 injector circuit short

• Code 81 – no. 1 ignition primary circuit open

• Code 82 – no. 2 ignition primary circuit open

• Code 83 – no. 3 ignition primary circuit open

• Code 84 – no. 4 ignition primary circuit open

• Code 85 – no. 5 ignition primary circuit open

• Code 86 – no. 6 ignition primary circuit open

• Code 91 – fuel pump circuit open

• Code 94 – fuel pump circuit short

LED 3 – Sensor circuits (5 V), “SENSOR FAULT.” For LIGHT ON, investigate possible fault codes:

• Code 12 – TPS circuit fault

• Code 13 – TPS below expected range

• Code 14 – TPS above expected range

• Code 16 – CPS, intermittent loss of sync

• Code 28 – shift switch malfunction

• Code 41 – PORT temp. sensor circuit fault

• Code 42 – PORT temp. below expected range

• Code 44 – BP sensor circuit fault

• Code 45 – BP below expected range

• Code 46 – BP above expected range

• Code 47 – AT sensor circuit fault

• Code 48 – AT sensor below expected range

• Code 49 – AT sensor above expected range

• Code 57 – High RPM with low TPS setting

• Code 58 – PORT operating temp. not reached

• Code 59 – STBD operating temp. not reached

• Code 67 – STBD temp. sensor circuit fault

• Code 68 – STBD temp. below expected range

• Code 71 – oil pressure circuit fault detected

• Code 72 – oil pressure below expected range

• Code 73 – oil pressure above expected range

• Code 74 – water pressure circuit fault detected

• Code 75 – water pressure below range

• Code 76 – water pressure above range

• Code 78 – analog 5V circuit overload detected

• Code 79 – starter solenoid circuit open

• Code 87 – exhaust pressure circuit fault

• Code 88 – exhaust pressure below range

• Code 89 – exhaust pressure above range

LED 4 – Engine overheat, EMM temperature or sensor, oil injection pump or sensor, “NO OIL / OVERHEAT.” For LIGHT ON, investigate possible fault codes:

• Code 23 – EMM temperature sensor circuit fault

• Code 24 – EMM temp. below expected range

• Code 25 – EMM temp. above expected range

• Code 29 – EMM temp. OVER range (flashing)

• Code 31 – engine temp. OVER range (flashing)

• Code 34 – oil injection pump circuit open

• Code 38 – oil pressure feedback not detected

• Code 43 – PORT temp. above expected range

• Code 69 – STBD temp. above expected range

The EMM stores valuable information about the outboard and its running history. This information can be used for troubleshooting and for checking outboard parts information. Program information is accessed through Diagnostic Software running on a laptop computer connected to the outboard.

IMPORTANT: For software help, refer to “Help Info” in the Evinrude Diagnostics software.

Locate the diagnostic connector on the engine. Remove the cover and install the Diagnostic Inter face Cable (P/N 437955).

1. Cover

2. Diagnostic interface cable

3. Engine harness diagnostic connector

Connect the 9-pin connector of the interface cable directly to the computer’s serial port.

The EMM must turn ON before it will communicate with any outside device. Power is normally sup plied to the EMM when the key switch is ON. Switched B+ (12 V) is supplied to the engine wire harness. Current enters the EMM at pin 21 (purple) of the EMM J1-B connector. Pin 9 (black) of the EMM J1-B connector provides ground to the EMM.

Static Information

Refers to information viewed when the outboard is NOT running. This includes manufacturing information.

The outboard model and serial numbers displayed on the Identity screen must match the identification label on the outboard swivel bracket.

Identity Screen

The serial number and cylinder location displayed on the Injector Coefficients screen must indicate the correct cylinder placement for all injectors.

Injector Coefficients Screen

Dynamic Information

Refers to specific information viewed while the outboard is running. Dynamic information updates quickly and allows the viewer to monitor voltage changes. The displayed information can be used for troubleshooting and checking outboard information.

Engine Monitor Screen

Service codes are fault conditions the EMM has identified. A service code may be stored as a result of some unidentified problem or condition. If no codes are displayed, the engine has no stored service codes.

Stored Faults

A stored service code represents a previous event or condition. Service codes are stored if they occur while the outboard is running.

The Stored Faults screen of the diagnostic program shows the code number, the number of times the event occurred, operating hours of first and last occurrence.

Stored Faults Review Screen

Hard Faults

A hard fault is a code that currently exists. Hard faults become stored faults only if the outboard is running.

Hard Faults Review Screen

Persistent Faults

The Persistent Faults screen provides a history of all previously stored codes, including code number, the number of times the event occurred, and operating hours of the last occurrence.

Persistent faults cannot be erased.

Static Tests perform diagnostic testing of specified components.

Static Tests Screen

Ignition Test

Use the diagnostic software to test each ignition circuit. Refer to Static Spark Test on p. 128.

Check each ignition circuit for continuity between the EMM and individual coil. Check the resistance of the ignition coil windings. Refer to IGNITION COIL TESTS on p. 141.

Fuel Test

Use the diagnostic software to test each fuel injector. The injector should make an audible click. Make sure the injector being monitored is wired correctly. If the injector activates, the EMM and injector circuits are not at fault. If the fuel injector(s) will not fire during the diagnostic tests, check the continuity of the injector circuit. Refer to Fuel Injector Resistance Test on p. 185.

Oil Injector

Use the diagnostic software to test the oil injection pump. Make sure the pump is wired correctly. If the pump activates, the EMM and oil injection circuit are not at fault. If the oil injection pump does not run during the static test, check voltage and continuity of pump circuit. Refer to OILING SYSTEM TESTS on p. 218. The resistance of the oil injection pump winding is approximately 22 Ω.

Fuel Pump

Use the diagnostic software to test the fuel pump. Make sure the pump is wired correctly. If the pump activates, the EMM and fuel pump circuit are not at fault. If the pump does not run during the static test, check voltage and continuity of pump circuit. Refer to Circulation Pump Resistance Test on p. 187.

Overheat

This test is used to simulate an overheat situation and is used to check the “ENG TEMP” or “HOT” circuit of the SystemCheck gauge.

Check Engine

This test is used to check the “CHECK ENGINE” circuit of the SystemCheck gauge.

Tachometer

This test is used to check operation of the tachometer circuit.

Dynamic tests are performed with the outboard running.

Dynamic Tests Screen

Fuel Test

The Fuel Test is performed with the outboard running (600 RPM minimum). This test momentarily disables one fuel injector circuit. By dropping one cylinder, RPM and running quality changes can be observed. Refer to the diagnostic software User’s Guide and Dynamic Tests on p. 120.

Ignition Test

The Ignition Test is performed with the outboard running (600 RPM minimum). This test momentarily disables the ignition circuit and fuel injection circuit to one cylinder. By dropping one cylinder, RPM and running quality changes can be observed. Refer to the diagnostic software User’s Guide and Dynamic Tests on p. 120.

Prime Oil

This test is used to cycle the oil injection pump for priming the oiling system. Perform this test with outboard running to activate oil injection pump.

Oil Injection Ratio (Used with XD100 oil only)

Evinrude E-TEC outboards can be programmed to run a reduced oiling rate. This feature should only be used with Evinrude/Johnson XD100 oil.

1. Oil control setting

Running an Evinrude E-TEC outboard on other grades of oil while set to the XD100 oil ratio will result in increased engine wear and shortened outboard life.

Powerhead Break-In

Use the diagnostic software to initiate break-in oiling. Break-in is a predetermined oiling program that runs for two hours of outboard operation, above 2000 RPM.

1. Break-in oil setting

IMPORTANT: Initiate Break-in programming for rebuilt powerheads.

Use the Ignition Timing screen of the diagnostic software to check and adjust EMM timing. EMM timing must be synchronized to crankshaft position.

Refer to TIMING ADJUSTMENTS on p. 157.

Perform timing verification after any of the following procedures:

• Powerhead replacement

• Crankshaft replacement

• Flywheel removal or replacement

• CPS replacement

• EMM replacement

• EMM software replacement

IMPORTANT: Make sure the timing pointer is set and the outboard reaches operating temperature before timing verification is performed.

Use the diagnostic software Settings screen to tell the EMM what the throttle position sensor voltage level is when the throttle plates begin to open.

Refer to TPS CALIBRATION on p. 159.

1. TPS Calibration button

Perform TPS Calibration after replacing or adjusting any throttle body or throttle linkage parts.

All fuel injectors are “compensated” and require software programming. DO NOT install an injector without updating the compensation software.

To install a service injector, click the “Replace” button on the Injector Coefficients screen and select the file for the replacement injector. Refer to Fuel Injector Installation on p. 194.

The purpose of this feature is to help troubleshoot cylinder combustion. The Evinrude Diagnostics Software program allows temporary adjustments to the fuel flow characteristics of the injectors. This feature should not be used by itself to identify a faulty injector. Adjustment can be made before the outboard is started or while it is running. Factory fuel flow settings are restored when the key switch is returned to the OFF position.

Engine reports provide service records and can be used to document the running history of an out board. Reviewing this information can help identify or resolve some service issues.

Clicking the print button in several windows of the diagnostic software allows the user to print engine data, or to export the information to a variety of computer file types.

1. Print button

2. Print/Export options

Engine Report Data Files

Software programs or “maps” are downloaded into the EMM prior to factory testing of the out board. Periodically, a new map may be available to enhance the operation of an outboard. Refer to the installation instructions provided with the program.

IMPORTANT: Software replacement requires the use of “Bootstrap” Tool, P/N 586551.

EMM Transfer is a feature that allows EMM replacement. Use the diagnostic software pro gram and follow the “help info” instructions provided in the program.

IMPORTANT: Whenever the EMM is replaced, timing verification must be performed. Refer to Timing Verification on p. 159.