Service Manual Evinrude E-TEC 40-60 HP Engine Managment Module [Emm Diagnostics]

LED Indicators

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

EMM Diagram

1. LED indicators
2. Electrical connectors

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 possible fault
codes: 17, 18, 26, 27.
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, 19, 24, 16, 19, 32, 41, 42, 44, 45, 46, 47,
48, 49, 58.
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
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 61 – cylinder no. 1 injector circuit short
• Code 62 – cylinder no. 2 injector circuit short
• Code 63 – cylinder no. 3 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 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 32 – oil switch signifies constant pressure
• Code 41 – engine temp. sensor circuit fault
• Code 42 – engine 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 58 – engine not reaching operating temp
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 34 – oil injection pump circuit open
• Code 38 – oil pressure feedback not detected
• Code 43 – engine temp. above expected

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, or a PDA, connected to the outboard

IMPORTANT: For software help, refer to “Help Info” in the Evinrude Diagnostics software, or to
the PDA software User’s Guide.

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

1. Diagnostic connector
2. Cover

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. On remote models, power is normally supplied 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 10 (purple) of the EMM J1-B connector.

IMPORTANT: Tiller or rope start models require temporary installation of a key switch at the engine harness connection and a 12 V battery and battery cables at the solenoid.

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

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. 116.
Check each circuit for continuity between the EMM and individual coil. Check the resistance of the ignition coil windings. Refer to Ignition Coil Tests on p. 128.

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. 164.

Oil Injector

Use the diagnostic software to test the oil injection pump electrical circuit. Monitor the voltage at pin 2 (blue wire) of oil tank connector. Voltage should drop while the static test is active.

IMPORTANT: Oil injection pump will not activate on 12 V. Use voltmeter to check circuit voltage.

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. 166. Fuel pump resistance is approximately 2 to 3 Ω.

Water Injector

This test activates the exhaust water valve solenoid.

Oil Fault

This test is used to simulate an oil pressure switch circuit malfunction and is used to check the “NO OIL” circuit of the System Check gauge.

Overheat

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

Check Engine

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

Tachometer

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

Dynamic tests are performed with the outboard running.

Dynamic Tests Screen

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 Dynamic Tests on p. 110.

Ignition Test

The Ignition Test is performed with the outboard running (600 RPM minimum). This test momentarily disables the ignition circuit to one cylinder. By dropping one cylinder, RPM and running quality changes can be observed. Refer to Dynamic Tests on p. 110.

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.

Power head 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 power heads.

This feature provides specific programming related to neutral switch operation. Tiller conversion kit installation requires programming of the EMM. Tiller operated models must be set to “TILLER.”

1. Starter mode setting

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. 142.

Perform timing verification after any of the following procedures:
• Power head 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.

Use Idle Adjust of the diagnostic software to increase or decrease the IN GEAR IDLE speed. This “Idle Offset” can be set for approximately 600 to 1000 RPM. The usable scale of this function is
is -250 to 100. Once “Idle Offset” is changed, the EMM will continue to control engine operation normally. Engine idle speed is not fixed. This idle speed adjustment offsets (increases or decreases) the basic EMM programming and will not set an absolute fixed speed.

1. Idle adjustment

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. 172.

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 outboard.
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 program 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. 143.

The System Check engine monitor warns the operator of conditions that could damage the
engine. The monitoring system consists of a dash mounted gauge with four light emitting diodes (LED), a warning horn, sensors on the engine and oil tank, and related wiring. The system is compatible with all Evinrude outboards with the Modular Wiring System (MWS). Gauges are available in two sizes: a 2-in. gauge with four LEDs or a 3 1/2-in. tachometer with LEDs.

2-Inch Gauge

3 1/2-Inch Tachometer