Service Manual Evinrude E-TEC 40-60 HP Engine Managment 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 all 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 and the EMM temperature returns to normal. Refer to SHUTDOWN MODE on p. 92.

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:

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
Monitors temperature at the top of 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 engine temperature exceeds 212°F (100°C), the EMM:

If engine temperature exceeds 248°F (120°C), the EMM:

The outboard will not restart, after a temperature related SHUTDOWN, until the engine temperature returns to normal. Refer to SHUTDOWN MODE on p. 92.

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 (104°F / 40°C below 2300 RPM), the EMM:

Oil Pressure Switch
The oil pressure switch monitors oil pressure in the oil distribution manifold. The switch requires approximately 7 psi (48 kPa) (nominal) to close.

If the switch fails to indicate pressure in the oil distribution manifold, the EMM:

If the switch indicates constant pressure (no changes) in oil distribution manifold, 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. 143.

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:

Initiates a service code 11

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 Adjustments on p. 56.

Crankshaft Position Sensor
The CPS is a magnetic device. It is mounted in the throttle body, 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
The powerhead mounted neutral switch provides a ground signal for the EMM to indicate shift linkage position. This allows the EMM to control idle speed variations for NEUTRAL or IN GEAR. Additionally, tiller models use the switch for 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.

Neutral RPM Limiter
This feature of EMM programming prevents engine damage due to excessive RPM if accelerated in NEUTRAL. Neutral engine speed is limited to 1800 RPM.

Exhaust Water Valve Activation (60 HP)
During acceleration, the EMM opens a valve that injects water into the exhaust housing. This water changes the tuning of the exhaust, allowing the engine to develop more midrange horsepower as the boat comes on plane.

Two conditions must be met to activate the valve:
• Throttle opening above 80%
• RPM between 2500 to 4600

The valve may not activate if the engine is accelerated slowly.

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 service code is cleared. Refer to SHUTDOWN MODE on p. 92.

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