How difficult is it to remove the EMM on a 2006 Evinrude E-TEC 60?

Removing the EMM from a 2006 Evinrude E-TEC 60 is manageable if you are comfortable handling electrical connectors and small cooling hoses, and the fixings are sound. Refitting the same working unit normally needs no programming, but a replacement requires the correct engine configuration and injector calibration data.

Check the diagnosis first

The EMM, or Engine Management Module, controls ignition, fuel injection and other engine functions. Failure to start, cutting out or a reported fault does not automatically mean the computer has failed.

Check the battery connections, engine earth connections, fuses and wiring plugs first. A loose terminal, corrosion or low cranking voltage can mimic an electronics failure.

If the engine still communicates with Evinrude diagnostic software, have its fault history and engine report saved before disconnecting anything. These give the repairer evidence and preserve information that may become inaccessible if the unit fails completely.

Check the model and serial number on the transom bracket too. An engine sold or registered in 2006 may belong to a different model year. Use those details when obtaining instructions or ordering parts.

Removing the EMM

The EMM sits beneath the cowling and is water-cooled. Removal means disconnecting its electrical plugs and cooling-water hoses, then releasing the mounting fixings. There is no need to dismantle the powerhead. Access, and any covers or brackets that need removing, depend on the exact model.

Switch off the ignition, remove the stop-switch clip and disconnect the battery negative lead before touching the EMM connections.

1. Remove the cowling and photograph the installation from several angles, including hose routing and wiring supports.
2. Label the cooling hoses and their connections before releasing the clips. Catch residual water and keep it away from exposed electrical contacts.
3. Release each connector's locking mechanism fully, then withdraw the plug by its body. Never pull the wires or prise against the pins.
4. Record the positions of any earth leads, spacers, washers or mounting bushes. Support the module while undoing its mounting fixings.
5. Lift the EMM clear and protect the connectors and hose openings from dirt and moisture.

Allow roughly an hour for a careful first removal, including photographs and labelling. Brittle hoses, seized screws or damaged connector locks can add considerably to that time. Stop if a plug will not release normally.

Protect connectors and cooling

Damaged pins, broken locking tabs and incorrect hose routing cause most costly mistakes. Inspect connectors for moisture, green corrosion, bent pins and seals displaced from their grooves. Do not push meter probes into connector sockets. Spreading a terminal can cause an intermittent fault after reassembly.