Page 1 of 6

Date: ______________________

Dealer Number: ____________________________________________

Dealer Phone: _____________________________________________

Technician Performing Tests: ________________________________

Diagnostic Worksheet
PLEASE HAVE AS MUCH INFORMATION AVAILABLE AS POSSIBLE *
BEFORE CALLING FOR ASSISTANCE
* See NOTE on last page

YOU CAN ALSO FAX THESE RESULTS TO:

(North American Dealers Only Please)

FAX NUMBER: (847) 689-6902

ATTENTION: _________________________

Prepared by the E-TEC Technical Team Revised: 6/28/2005

 Page 2 of 6

Section 1: Problem Description

Description of Runability Issue: _____________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

Did Warning Horn Sound? Y / N Did Engine Go Into SAFE Mode? Y / N

Did any System Check lights illuminate? Y / N Which one(s)?: ___________

Any EMM LEDs NOT illuminated while cranking? Y / N Which one(s)?: ___________
(Top LED is #1, bottom LED is #4)
Any EMM LEDs illuminated while running? Y / N Which one(s)?: ___________
(Top LED is #1, bottom LED is #4)
Prop Size & Description: ______________________________

Type of Boat: ________________________________________ Type of Oil in reservoir: _______________

Set-Up: Tiller / Remote If tiller, is starting by: Key-Switch / Push-Button

Maximum RPM @ WOT: (per boat tachometer) __________________

Section 2: DYNAMIC INFO / MONITOR

- Use one of the available diagnostic programs to collect the following information -

Diagnostic Software Used: PC / PDA version # _______________

TPS Calibration: @idle: _______ @pick up: _______ @WOT: _______

TPS Voltage: @idle: _______ @pick up: _______ @WOT: _______

System Voltage: @idle: _______ @1800 rpm: _______ @ 3000 rpm:_______ @WOT: _______
Compare above readings with actual voltage at injector, see Section 6, page3.

Battery Voltage: @idle: _______ @1800 rpm: _______ @WOT: _______

Engine Temp Readings *cold: _______ @ idle: _______ @ 3000+rpm: _______

Compare Engine Temp Readings with actual temps *cold: ______ @ idle: ______ @ 3000+rpm: ______
using a "Raytek-type" infrared temp gun

EMM Temp Readings *cold: _______ @ idle: _______ @ 3000+rpm: _______

* Check before running!

Section 3: STATIC TESTS

Fuel Injectors: 1) ________ 2) ________ 3) ________ 4) ________ 5) ________ 6) ________

Ignition Firing: 1) ________ 2) ________ 3) ________ 4) ________ 5) ________ 6) ________

Fuel Pump: Does it activate? Y / N

Tachometer: __________ (Test generates 2441 rpm signal for inline E-TEC)

Prepared by the E-TEC Technical Team Revised: 6/28/2005

 Page 3 of 6

Section 4: DYNAMIC TESTS

Run engine at RPM where runability issue exists: What is that RPM or RPM range? _________

Drop Fuel: 1) ________ 2) ________ 3) ________ 4) ________ 5) ________ 6) ________

(Record RPM when cylinder is dropped)

Drop Ign & Fuel: 1) ________ 2) ________ 3) ________ 4) ________ 5) ________ 6) ________
(Record RPM when cylinder is dropped)

Injector Adjust: 1) ________ 2) ________ 3) ________ 4) ________ 5) ________ 6) ________

(Record amount of change (+ or -) where engine runs best)

Disable Idle Controller (if an idle issue) Note: This feature only available with the pc diagnostic programs.
Use a pair of insulated spark plug boot pliers to individually remove the spark plug leads.

Pull plug wire: 1) ________ 2) ________ 3) ________ 4) ________ 5) ________ 6) ________

(Record RPM when cylinder is dropped)

Section 5: TIMING ADJUST

Timing Verified? Y / N What was indicated on light? _____
What was indicated in diagnostic program? _____

Section 6: Other Checks & Tests (not requiring use of diagnostic software)

Outside air temperature _______ Barometric pressure _______ (Do NOT use reading from EMM)

Have all ground connections been cleaned and tightened? Y / N

(battery, starter solenoid & lower ignition coil)

Injector Circuit Voltage at Injectors (Measure at 3-pin connector with Test Probe Kit p/n
342677. Use a digital voltmeter / engine running)
Compare above readings with system voltage reading from EMM, see page 2.

@idle: _______ @1800 rpm: _______ @ 3000 rpm:_______ @WOT: _______

Primary Voltage at Ignition Coils (Measure at 3-pin connector with back-probe adapter p/n
342677. Use a peak reading voltmeter / engine running)

1) ________ 2) ________ 3) ________ 4) ________ 5) ________ 6) ________

Ignition Spark Check: (Cranking - Use Spark Board, Leave Spark Plugs Installed)

1) ________ 2) ________ 3) ________ 4) ________ 5) ________ 6) ________

Compression Test: (Engine warm, throttle open)

1) ________ 2) ________ 3) ________ 4) ________ 5) ________ 6) ________

Cylinder Leak-down Test:

1) ________% 2) ________% 3) ________% 4) ________% 5) ________% 6) ________%

Spark Plugs: Part # ________________ Gap: ____________ New: Y / N

Prepared by the E-TEC Technical Team Revised: 6/28/2005

 Page 4 of 6

Section 6: Other Checks & Tests (continued)

Fuel Condition:
Sample From Tank _________ Sample From Vapor Separator __________
Is there any fuel in the Vapor Separator Vent Hose? (Remove hose from intake manifold only!) Y / N

Is there any fuel in the Lift Pump Pulse Hose? Y / N

(Substitute a piece of clear tubing, run engine and watch for fuel)

Fuel Pressure (Low): _____ PSI Is pressure steady? Y / N

Fuel Pressure (High): Running @ idle _____ PSI Is pressure steady? Y / N

Running above 3000 rpm _____ PSI Is pressure steady? Y / N

Fuel Pressure (High) after 10 minute period leaks down to: ________ PSI

Boat Fuel System Vacuum Test: __________ in.Hg.

Stator Resistance (yel- yel/wht) _________, (brn - brn/wht) _________, (org - org/wht) _________

Stator Cranking Voltage (use adapter p/n 5005799 or 5006211) ________________

What is the gap between the throttle cam and roller with linkage against idle stop? _________

Section 7: STATIC INFO / IDENTITY (Either copy the information in the spaces below, or provide a
print out of an engine report for this section.

Engine Model: __________________________ Engine Serial # : ________________________

Software Version: _______________________ Software Revision: ______________________

EMM Serial #: __________________________ Start Cycles: ______________ (Lap top only)

Engine Hours: __________________________

List all Active Codes: __________________________________________________

List all Stored Codes: __________________________________________________

PROFILES
RPM Profile: ________ ________ ________ ________ ________ ________ ________
0-500 500-1000 1-1500 15-2000 2-2500 25-3000 35-4000

________ ________ ________ ________ ________ ________

4-4500 45-5000 5-5500 55-6000 6000+ MAX RPM

*Engine Temp
Profile: ________ ________ ________ ________ ________ ________ ________
*In °Celsius -10 - 0 0 - 10 10 - 20 20 - 30 30 - 40 40 - 50 50 - 60

________ ________ ________ ________ ________ ________

60 - 70 70 - 80 80 - 90 90 - 100 100 - 110 MAX Temp

*EMM Temp Profile: ________ ________ ________ ________ ________ ________ ________
*In °Celsius -10 - 0 0 - 10 10 - 20 20 - 30 30 - 40 40 - 50 50 - 60

________ ________ ________ ________ ________ ________

60 - 70 70 - 80 80 - 90 90 - 100 100 - 110 MAX Temp
Prepared by the E-TEC Technical Team Revised: 6/28/2005
 Page 5 of 6

Section 7: STATIC INFO / IDENTITY (Continued)

OIL CONTROL

Type of Oil in reservoir: _________________ Oil System Configured for: TCW-3 / XD-100

Is break-in complete? Y / N How much break-in time remaining? ____________ (minutes)

STARTER MODE

Engine is configured as a: Tiller / Remote Was it configured correctly? Y / N

INJECTOR INFORMATION Note: (E-TEC injector coefficients may be negative numbers)

Injector #1 Injector Serial #: ______________________________

Coefficient A: _______________
Coefficient B: _______________
Coefficient C: _______________
Coefficient D: _______________
High Pressure: _____________________
Delay: _____________________
Cycle Counts: _____________

Injector #2 Injector Serial #: ______________________________

Coefficient A: _______________
Coefficient B: _______________
Coefficient C: _______________
Coefficient D: _______________
High Pressure: _____________________
Delay: _____________________
Cycle Counts: _____________

Injector #3 Injector Serial #: ______________________________

Coefficient A: _______________
Coefficient B: _______________
Coefficient C: _______________
Coefficient D: _______________
High Pressure: _____________________
Delay: _____________________
Cycle Counts: _____________

continue on next page for V4 or V6 models.

Prepared by the E-TEC Technical Team Revised: 6/28/2005

 Page 6 of 6

INJECTOR INFORMATION Note: (E-TEC injector coefficients may be negative numbers)

Injector #4 Injector Serial #: ______________________________

Coefficient A: _______________
Coefficient B: _______________
Coefficient C: _______________
Coefficient D: _______________
High Pressure: _____________________
Delay: _____________________
Cycle Counts: _____________

Injector #5 Injector Serial #: ______________________________

Coefficient A: _______________
Coefficient B: _______________
Coefficient C: _______________
Coefficient D: _______________
High Pressure: _____________________
Delay: _____________________
Cycle Counts: _____________

Injector #6 Injector Serial #: ______________________________

Coefficient A: _______________
Coefficient B: _______________
Coefficient C: _______________
Coefficient D: _______________
High Pressure: _____________________
Delay: _____________________
Cycle Counts: _____________

* NOTE: This worksheet is intended to be used as a guide for troubleshooting. Keep in mind,
warranty may not pay labor time to conduct every test listed here - For example, if you are
troubleshooting an oil issue, don't expect warranty to pay for testing the ignition system.

Prepared by the E-TEC Technical Team Revised: 6/28/2005