5006527 EVINRUDE VALVE, Pressure relief Assy.

This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4580" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
Termination Date
November 30, 1999Problem
Single wire air and oil temperature sensors ground to the engine block. This can cause galvanic corrosion of vessel hulls, inaccurate readings, or inadequate sensor life. These single wire sensors should be replaced with two wire type sensors.
Inlet air and oil temperature sensors are only on engines with Premium Electronic Instrument Panels.
Affected Product
Model & Identification Number
3508B (3DM82-85, 3DM88, 3DM89, 3DM92, 3DM94-96, 3DM101-103, 3DM106, 3DM108-110, 3DM112-117, 3DM123-132, 3DM134-139, 3DM149 6PN161 , 6PN252, 6PN285-287, 6PN293, 6PN328, 6PN330, 6PN338, 6PN384, 6PN406, 6PN426, 6PN427, 6PN432, 6PN454 2HW105-106 , 2HW113-118)
3512B (8EM247, 8EM248, 8EM253-256, 8EM260-272, 8EM274, 8EM275, 8EM279-288, 8EM293, 8EM294, 8EM297, 8EM298, 8EM301, 8EM303-308 8RM136 , 8RM171-174, 8RM227, 8RM229-232, 8RM240, 8RM262, 8RM272-274, 8RM278, 8RM306 1PW342 , 1PW346-348 4AW234 , 4AW237, 4AW245, 4AW249, 4AW258, 4AW281, 4AW285, 4AW302-304)
3516B (7RN229, 7RN295, 7RN298-303, 7RN383, 7RN387, 7RN394, 7RN396-399, 7RN401, 7RN412-414, 7RN416-418, 7RN421, 7RN428-439, 7RN451, 7RN453-458, 7RN460, 7RN495-496, 7RN532, 7RN533, 7RN540-545, 7RN561, 7RN563, 7RN587, 7RN588, 7RN590, 7RN591, 7RN598-601, 7RN604, 7RN607, 7RN614, 7RN638-640 9AN105-107 , 9AN110-121, 9AN123, 9AN124, 9AN126, 9AN127, 9AN129-131, 9AN135-151 1NW112 2FW129-133 , 2FW158-166)
Parts Needed
1 - 165-4099 EMS-II Module1 - 113-7884 EMS-II Module Film1 or 2 - 129-9191 Temperature Sensor *1 - 5P-4481 O-Ring Adapter1 - 6V-4589 O-Ring Seal1 - 132-9434-01 Wiring Harness - 124-0289 Wiring Harness Clips ** - 8M-2771 Wiring Harness Clips** - 4P-7428 Wiring Harness Clips** - 4P-7429 Wiring Harness Clips** - 4P-7581 Wiring Harness Clips** - 4P-8134 Wiring Harness Clips** - 6V-1889 Wiring Harness Clips** - 9X-6772 Wiring Harness Straps**Teflon Pipe Sealant (or equivalent)
*If replacing a 127-9869 Wiring Harness it is necessary to have two new 129-9191 Temperature Sensors. If replacing a132-9434 Wiring Harness it is only necessary to have one new129-9191 Temperature Sensor because one 129-9191 Temperature Sensor is already installed in the air inlet sensor port.**Use as needed***Required only when replacing a 4W9972 oil temp sensor. If the 1329434 Harness is ordered, the latest change level (01) will be shipped automatically.
Action Required
See Attached Rework Procedure.
Service Claim Allowances
This is a 4.0-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
TOOLS NEEDED
- ' Allen Wrench- ' Allen Wrench- 1-' Combination Wrench- ', 7/8" Combination Wrench- ' Wrench- Small Adjustable Wrench- Side Cuts- Deutsch extraction tool (for 16-18 gauge wire)1. Turn the ECS Switch to the OFF/RESET position. Open the Electronic Instrument Panel (EIP). Using a 5/32 allen wrench, disconnect the 40-pin connector from the back of the EMS-II Module. Then using a 1/8" allen wrench, and a small adjustable wrench, remove the old 155-8653, 153-1929, 149-0339, 135-6957, 127-0336, or 115-4636 EMS-II Module from the EIP.2. Install the new 165-4099 EMS-II Module. First apply the 113-7884 EMS-II Module Film to the face of the new 165-4099 EMS-II Module. Then, using a 1/8" allen wrench, a small adjustable wrench, and the hardware from the old module, attach the new EMS-II Module to the instrument panel. Using a 5/32 allen wrench, connect the 40-pin connector to the back of the new EMS-II Module. Close the EIP. 3. As you perform this step, it may be helpful to take note of the routing of the old harness for future reference. Remove the current 127-9869 (2-wire) or 132-9434-00 (3-wire) Wiring Harness from the engine. In doing this, pins must be removed using a Deutsch extraction tool from the Customer Connectors "C" and "D" located on the underside of the EIP (see Table 1 or 2 below). 4. Remove the old 4W-9972 Oil Temperature Sender using a ' wrench.5. Remove the old 7N-8532 Air Inlet Temperature Sender using a ' wrench. If the engine has a 129-9191 Inlet Air Temperature Sensor instead of the 7N-8532, do not remove the sensor. 6. Apply teflon tape to one of the new 1299191 Sensors and install the 5P4481 O-Ring adapter. Then press fit the 6V-4589 O-Ring Seal on to the O-Ring Adapter. Lubricate O-Ring Seal before installation. Install this sensor-adapter-seal assembly into the oil temperature port using a ' wrench.7. If a 7N-8532 Inlet Air Temperature Sensor was removed, apply teflon pipe sealant (or equivalent) to the second 129-9191 Temperature Sensor and install into the air temperature port using a' wrench.8. Connect the new 132-9434-01 wiring harness to the sensors and Customer Connectors "C" and "D" according to the tags on the wiring harness (see Table 3 below). 9. Using 9X-6772 straps, install the new wiring harness to the engine in a similar manner that the old harness was installed. If possible, use existing clips to secure the new wiring harness to the engine. If no clips on the engine can easily be used to secure the new harness, it may be necessary to install additional clips. The purpose of this step is to securely attach the new wiring harness to the engine and other existing wiring harness using a combination of straps and clips. Wiring Harness should not rub on any engine component.10. Set the EMS-II to English or Metric units. To do this turn the ECS Switch to the COOLDOWN/STOP position. Enter Units Mode (Mode 4) by holding down the CLEAR/MODE Switch until "-4-" appears in the LCD. When the Main Display Module enters Units Mode, the LCD will display the current setting, "US" when set to US units and "SI" when set to Metric units. Press the "SCROLL" Switch to toggle the units between "US" and "SI".11. Start engine and allow to warm to operating temperature.12. Check for leaks around the newly installed sensors.13. Verify operation of the new sensors and EMS-II panel. Use Mode 1 to view readout