Service Manual 5007213_Evinrude E-TEC 115-200 HP Engine Management Module [Sensors And Functions]

Sensor inputs and internal EMM controllers are used to control outboard operation. Use the Evinrude Diagnostics Software program to troubleshoot the sensors. Refer to Evinrude EMM Service Code Chart at back of manual for complete list of al engine fault codes.

Internal sensors are NOT serviceable. Reprogramming or replacement may be required to
resolve EMM related issues.

EMM Temperature Sensor

Monitors the temperature of the fuel injector driver circuits.

If the EMM temperature exceeds 176°F (80°C) or the circuit fails, the EMM:

If EMM temperature exceeds 212°F (100°C) or the circuit fails, the EMM:

IMPORTANT: The outboard will not restart until the engine cools below 212°F (100°C ) and the EMM temperature returns to normal. Refer to SHUTDOWN MODE on p. 103.

If EMM temperature is less than -22°F (-30°C) or the circuit fails, the EMM:

Sensor indicates less than -71°F (-57.4°C) or greater than 314°F (156.9°C) a sensor circuit fault is detected and the EMM:

55 V Circuit Sensor

Monitors the EMM’s 55 V alternator circuit.

If system voltage exceeds 57 volts, the EMM:

If system voltage is below 45 volts with outboard running 500 to 1000 RPM or is below 52 volts with outboard running above 1000 RPM, the EMM:

12 V Circuit Sensor

Monitors the EMM’s 12 V alternator circuit.

If battery voltage exceeds 15.5 volts, the EMM:

If battery voltage is below 12 volts with outboard running 500 to 2000 RPM OR is below 12.5 volts with outboard running above 2000 RPM, the EMM:

Barometric Pressure Sensor

Supplies the EMM with barometric pressure reading to compensate for changes in altitude and air density.

If the BP sensor is out of the expected range (below 13.3 KPa or above 119 0 KPa), or the sensor or circuit fails, the EMM:

If the BP sensor is below expected range (below 70 KPa), the EMM:

If the BP sensor is above expected range (above 105 KPa), the EMM:

Exhaust Pressure Sensor

Monitors exhaust pressure during all running conditions to compensate for engine loads.

If the exhaust pressure sensor is not in the expected range (< 0.12 V or > 4.88 V ), or the sensor or circuit fails, the EMM:

If the exhaust pressure is below expected range (below 40 in. water), the EMM:

If the exhaust pressure is above expected range (above 80 in. water), the EMM:

The EMM provides a 5 V DC signal for sensor circuits. It monitors all sensor voltage inputs and compares them to predetermined acceptable ranges. Inputs that fall outside of the acceptable range initiate service codes.

Air Temperature Sensor

Monitors the air temperature at the throttle body. The air temperature sensor is a negative temperature coefficient (NTC) thermistor. As temperature increases, the resistance of the sensor decreases resulting in a lower voltage reading at the EMM. Temperature decreases result in a resistance increase and a higher voltage reading at the
EMM.

If the AT sensor voltage is out of the expected range, or the sensor or circuit fails, the EMM:

Engine Temperature Sensor(s)

Monitor the temperature for each cylinder head. The sensor is a negative temperature coefficient thermistor (NTC). It provides engine temperature information to the EMM. The EMM uses this information to control engine operation and to activate the overheat warning system.

If PORT cylinder head temperature exceeds 194°F (90°C), the EMM:

If STARBOARD cylinder head temperature exceeds 194°F (90°C), the EMM:

If EITHER cylinder head temperature exceeds 248°F (120°C), the EMM:

The outboard will not restart, after a temperature related SHUTDOWN, until the engine temperature is BELOW 120°C (returns to normal. Refer to SHUTDOWN MODE on p. 103.

If sensor values are below -15°F (-26.1°C) or above 331°F (166.5°C), the EMM:

If sensor values are below -4°F (-20°C), the EMM:

If engine does not reach operating temperature on PORT cylinder head (122°F / 50°C below 2300 RPM) in 10 minutes, the EMM:

If engine does not reach operating temperature on STARBOARD cylinder head (122°F / 50°C below 2300 RPM) in 10 minutes, the EMM:

Oil Pressure Sensor

The oil pressure sensor monitors oil pressure in the oil distribution manifold.
If the sensor fails to indicate pressure in the oil distribution manifold, the EMM:

If outboard has been run for more than 5 hours with the existance of NO OIL faults (codes 34 & 38), the EMM:

IMPORTANT: The outboard will restart for one minute intervals until problem is resolved and code is cleared. To clear code use the diagnostic software propram.

If the sensor circuit fails to indicate within a specific range or fails, the EMM:

If the sensor circuit indicates below expected range (<.5 V), the EMM:

If the sensor circuit indicates above expected range (> 4.5 V), the EMM:

Throttle Position Sensor

The throttle position sensor is a rotary potentiometer connected to the throttle plate shaft. The sensor receives a voltage signal from the EMM. As the throttle lever is rotated, the EMM receives a return voltage signal through a second wire. This signal increases as the TPS lever is advanced. A third wire provides a ground circuit back to the EMM.

Refer to TPS CALIBRATION on p. 159.

If the TPS sensor or circuit fails (below 0.15 volts or above 4.95 volts), the EMM:

IMPORTANT: Once a TPS circuit fault has been detected, the outboard will not accelerate above idle speed. To reset, stop the outboard and correct the fault.

If the TPS sensor circuit indicates below 0.2 volts, the EMM:

If the TPS sensor circuit indicates above 4.85 volts, the EMM:

If the TPS sensor circuit indicates above 0.65 volts when the key is turned to the ON position, the EMM:

If the outboard is started, the code is stored.

If code 11 is present as both a Hard Fault and a Stored Fault, refer to Control Cable Installation on p. 60.

Crankshaft Position Sensor

The CPS is a magnetic device. It is mounted on the reed plate, adjacent to the flywheel.
Encoder rib spacing on the flywheel coincides with crankshaft position. As the encoder ribs of the flywheel pass the magnetic field of the CPS, an AC voltage signal is generated. The EMM uses this signal to identify crankshaft position and speed, generate a tachometer signal, and control fuel and ignition timing.

If the sensor is damaged or the signal is intermittent (10 instances), the EMM:

Approximate air gap between CPS and flywheel encoder ribs is .073 (1.85 mm).

Use the engine Monitor screen of the Evinrude Diagnostics Software program to check CPS
operation. The outboard should indicate an RPM reading while cranking. If the CPS or its circuit fails, no RPM reading will be generated and the outboard cannot run.

Neutral Switch (V4 Models)

The powerhead mounted neutral switch provides a ground signal for the EMM to indicate shift linkage position when a tiller kit has been installed. This allows the EMM to provide start in gear protection. Fuel and ignition functions are turned off on tiller models if the neutral switch is not activated.

If the switch is not functioning properly, the EMM:

The engine Monitor screen of the diagnostic program displays switch position, NEUTRAL or IN GEAR. Make sure switch is operating properly.

ROM Verification

The EMM runs through a self-test of programming every time it is turned ON. Service code 15 indicates a programming (software) issue. Reprogram the EMM with the correct software program to resolve.

Idle Controller

The idle controller reacts to engine operating conditions. Fuel and ignition timings are altered to maintain a specific RPM when engine is cold or warm. The controller is inactive when TPS is advanced from idle position.

RPM Limiter

This feature of EMM programming prevents engine damage due to excessive RPM. At 6250
RPM, fuel and ignition to the cylinders is shut off. Normal engine operation resumes when engine RPM returns to the specified range.

Exhaust Valve (V4 Models)

The EMM controls a valve that switches between two exhaust paths to provide optimum exhaust tuning under various running conditions. At slower speeds and under acceleration, the system opens a longer path, allowing the engine to develop more midrange horsepower as the boat comes on plane. At higher RPMs, the path is shortened for maximum high speed performance.

Shutdown, Code 57

This feature of EMM programming monitors engine operation for abnormally high RPM with a
low TPS position. If this condition is detected, the EMM:

IMPORTANT: The outboard will not restart until the stored service code is cleared; and the EMM is turned OFF and then ON again. Refer to SHUTDOWN MODE on p. 103.

Fault Codes

Refer to Evinrude EMM Service Code Chart at back of manual for complete list of all engine fault codes.