5041433 EVINRUDE CARBURETOR ASSEMBLY (EL)

Diagnostic Codes
For further explanation of diagnostic codes refer to Troubleshooting.ACTIVE Diagnostic Codes
Diagnostic codes are used by the 3406E System to warn the operator of a problem and indicate to the service technician the nature of the problem. Some codes are used only to record an event and do not indicate problems that need repair.An ACTIVE diagnostic code represents a problem that should be investigated and corrected AS SOON AS POSSIBLE. Repairing the cause of an ACTIVE code will cause the active code to be cleared.When an ACTIVE code is generated, the diagnostic lamp will turn ON and remain ON, blinking every five seconds. If the condition generating the fault occurs only for a brief moment, the lamp will go OFF after five seconds and the code will be LOGGED.There are a few codes that are not generated by an electrical/electronic problem and are recorded as events. Examples of these events include low oil pressure and high coolant temperature. These events are caused by mechanical problems and do not require electronic troubleshooting.Some Diagnostic Codes cause the 3406E System to make major changes in engine operation or limits.EVENT Diagnostic Codes
When the ECM generates a diagnostic code, it logs the code in permanent memory within the ECM. The ECM has an internal diagnostic clock and will record the hour EACH time a code is logged. Knowing when and how often the code was generated can be a valuable indicator when troubleshooting intermittent problems. Logged codes can be retrieved or erased using an electronic service tool.Diagnostic Codes that are logged repeatedly may indicate a problem that needs special investigation. Codes that are logged only a few times and do not result in operator complaints, may not need attention until a scheduled maintenance interval. The most likely cause of an intermittent problem is a faulty connection or damaged wiring. Least likely is the ECM itself.Electronic Service Tools
The Caterpillar Electronic Service Tools for the electronic control system are designed to help the service technician analyze and locate faults or problems within the system. An electronic service tool, Caterpillar Electronic Technician (ET) or Electronic Control Analyzer Programmer (ECAP), is required to perform some sensor calibrations and to read or change engine parameters.The electronic service tool communicates with the Electronic Control Module to read diagnostic codes and various sensor output signals such as engine rpm or inlet manifold air pressure and controls electronic calibration of sensors through the ECM.Caterpillar Electronic Technician (ET) requires a personal computer with the ET software installed and a Caterpillar Communication Adapter to translate from the data link to the computer.The Electronic Control Analyzer Programmer (ECAP) tool has small plug-in modules, called Service Program Modules (SPM), to adapt the basic tool to the specific Caterpillar electronic control application.The ECAP (requires PWM adapter to measure at sensor) can measure Pulse Width Modulated (PWM) signals such as the signal produced by the Throttle Position Sensor.Installation/Removal Of The Speed/Timing Sensor
Engine (Left Side View)(1) Speed/timing sensor.(2) Speed/timing connector P20/J20. This procedure can be used for the backup speed/timing sensor also. Refer to Electronic Control System Components for the sensor location.1. Disconnect speed/timing connector P20/J20 (2) and inspect for corrosion, bent or missing pins and sockets, and mismating, broken wires, etc.2. Remove the speed/timing sensor (1) from the front gear cover.3. Examine the plastic end of the sensor for signs of wear or contaminants such as metal filings. The plastic end of the speed/timing sensor should have no contaminants or show no wear.4. Use a screwdriver to carefully pry the plastic sensor end to the fully extended position [approximately 4.775 mm (.1880 in) beyond the metal housing of the sensor].5. Gently push in on the plastic end of the sensor. The plastic end should be firm and resist movement in the retract direction. If there is no resistance replace the sensor.6. To install the speed/timing sensor (1), first perform the sensor inspection described in Steps 3 through 5.7. Assure that the slip head is fully extended.8. Visually inspect the timing wheel position in order to ensure that the slip head will not fill one of the slots of the timing wheel. If necessary, turn the crankshaft in order to rotate the timing wheel to a position that will not allow the sliphead to fill a slot on the timing wheel.
Locating Top Center (Left Side Of Engine)(3) Bolt.(4) Timing bolt location.(5) Cover.
Using 9S9082 Engine Turning Tool(3) Bolt.(6) 9S9082 Engine Turning Tool.a. Remove two bolts (3) and remove cover (5) from the flywheel housing to open the hole for engine turning.b. Put one bolt (3) in the timing bolt location (4) located approximately 127 to 152 mm (5 to 6 in) above the hole in the flywheel housing for engine turning.c. Use 9S9082 Engine Turning Tool (6) and a 1/2 inch drive ratchet wrench to turn the engine flywheel in the direction of normal engine rotation (counterclockwise when viewed from the flywheel end) until the timing bolt engages with the threaded hole in the flywheel.d. Remove bolt (3).9. Install the speed/timing sensor without the washer. Tighten the speed/timing sensor to 40 5 N m (30 4 lb ft).10. Remove the speed/timing sensor. Do not move the sliphead.11. Install the washer on the speed/timing sensor.12. Install the speed/timing sensor.13. Calibrate the engine timing. Refer to Engine Timing Calibration in Troubleshooting.Throttle Position Sensor Adjustment
The throttle position sensor (TPS) is used to provide a throttle signal to the Electronic Control Module (ECM). Sensor output is a constant frequency signal whose pulse width varies with throttle position. This output signal is referred to as either "Duty Cycle" or a "Pulse Width Modulated (PWM)" signal and is expressed as a percentage. When correctly adjusted, the TPS will produce a "Duty Cycle" signal of 15 percent to 20 percent at the low idle throttle position and 80 percent to 85 percent at the maximum throttle position. This signal is translated by the ECM into a "Throttle Position" signal of three percent at low idle and 100 percent at maximum throttle.Fuel System
Either too much