Help with fault codes, please.

Arminius

Well-Known Member
Oct 30, 2019
1,060
Seattle
Boat Info
Bowrider 200 Select, 2003
Engines
5.0L MPI, 260 hp w/Alpha 1 Drive
I'd appreciate a referral to a manual explaining the possible fault codes of my 2003 5.0 L MPI
w/o Smartguard, S/N OM 600590 or some guidance. Not young, I've watched and used the codes as they came into my autos, trucks and motorcycles. I now know that the first thing to do with any performance concern or CEL (engine light) is to read the codes and Google the OBD2 meaning and similar complaints and resolutions for my model.
They appear to be more obscure and less useful with the boat.
First, I found a chart of the beep codes: Ignition on and there is a tone to indicate they are active. Then there are a variety of malfunctions which result in a constant tone, steady beep or 2 bp/min and a % power reduction. Constant tone and up to a 94% power reduction indicate low sea water or oil pressure, overheating, or overreving. Fix the fault and the tone and power reduction presumably go away.
Next, you have stored fault codes in the engine computer. My cellphone reads my cars with a
$25 adapter and a free app. The boat takes a $400 Rinda scan tool but the codes can also be read by shorting contacts on the diagnostic plug and counting the voltage pulses as LED flashes or needle swings on your meter. Unfortunately, there seems to be little useful info in the codes (guess I have MEFI-4):
"18 GM EFI TROUBLE CODE CHART MEFI-3 & MEFI-4 Code Description 13 Oxygen Sensor 1 or 2 Malfunction, 14 Coolant Sensor Voltage High (cold), 15 Coolant Sensor Voltage Low(hot), 21 Throttle Position Sensor Voltage High, 21 Throttle Position Sensor Voltage Skewed High, 22 Throttle Position Sensor Voltage Low, 23 Manifold Air Temperature Sensor High (cold), 24 Speed Sensor Inactive (if installed), 25 Manifold Air Temperature Sensor Low (hot), 31 Governor Not Tracking, 32 EGR Valve Not Tracking, 33 Manifold Absolute Pressure Sensor High, 34 Manifold Absolute Pressure Sensor Low, 41 Electronic Spark Timing Open Circuit, 42 Electronic Spark Timing Grounded Circuit, 43 Electronic Spark Control Detects Continuous Knock, 44 Knock Sensor 1 or 2 Inactive, 51 Calibration Checksum Error, 54 Oxygen Sensor 1 or 2 Lean, 55 Oxygen Sensor 1 or 2 Rich, 61 Fuel Pressure Sensor High, 62 Fuel Pressure Sensor Low, 63 Fuel Temperature High, 64 Fuel Temperature Low, 81 See Scan Tool* * Scan tool will display specific details on the type of Code 81 that is set. Code 81 is associated with a variety of system faults." https://www.rinda.com/acro/Merc_manual_v5.pdf
Apparently that's it! I'd like to know if the MAP is at fault (as my MB mass air sensor was always a likely suspect) but counting the pulses would reveal that w/o spending $400 or dragging the boat to the marina. Any further explanation would be appreciated, especially if the "specific details" disclosed under Code 81 are of the useful type. Incidentally, my boat doesn't have any problem but I thought I would use this Corona time positively.
 
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I’ve got the Merc service manual for the 8.1/496 engine of the same vintage. The electronics related to engine and ignition are not included. I’ve also got the SmartCraft rigging manual, also for the same time period, and it is also lacking anything on the how, or why. So my guess is that there must be a manual specific to engine fault codes/workings of the electronics.

The Rinda tool might be your best option. Keep in mind, marine engine parts, especially electronics, are often substantially more expensive then the automotive counterpart. You might consider going easy on shorting terminals. This is definitely not the time for Jack and a bigger hammer.
 
Figure out which ECM you have and take from there
Merc went from the mefi 3 to the 555 around that period. They never used the mefi 4. V/P did though
The mefi 3 is real simple compared to the 555
 
I would like to know where I can find more documentation. My beep fault chart shows various problems creating 2 beeps per minute without directions as to how to discriminate amongst them without the SC1000 System Monitor (Smart Guard?). I had the 4 codes on my Merc outboard laminated and fastened to the dash as problems never happen in calm waters.

Here is a Mercruiser academic reading the fault codes with a meter:
 
Figure out which ECM you have and take from there
Merc went from the mefi 3 to the 555 around that period. They never used the mefi 4. V/P did though
The mefi 3 is real simple compared to the 555
Thank you. The Rinda manual said my manufacturing period used MEFI 4 and I could have been off on a tangent already. There is a plate on the ECM on the port side behind the riser with numbers. I will pursue them.
 
You need MerCruiser manual #36 ECM 555. Google it and you’ll find a free download site. This states it applies to engines OM 300000 (OOPs! 300,000 not 3,000,000, sorry) and above.
 
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Scoff and Henry are correct. One thing that should have been a quick tipoff is in that video, it's an EFI system. You have an MPI system.
 
You need MerCruiser manual #36 ECM 555. Google it and you’ll find a free download site. This states it applies to engines OM 3000000 and above.
Thank you very much. I have the big #31 but the Supplement to #31 did not look useful.

This is crazy but if you overrev this engine it goes into Guardian Mode and limits rpm until the dealer clears the codes! The whole point of trimming my Hydrostream air entrapment hull w/ the 220EFI Merc outboard was to go fast enough that the hull got light and you could go even faster. Course you were ventilating and overreving at the least ripple.
I no longer wonder how dealers stay in business!

To clear the codes on the Mercruiser, paperclip A and B together to enter the Service Mode. Turn the ignition on but do not start. Firewall the throttle and return to neutral. Go out and do it again!
https://www.offshoreonly.com/forums...e-marine-efi-code-tool-less-than-$1-00-a.html
 
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Thank you very much. I have the big #31 but the Supplement to #31 did not look useful.
31 is the engine mechanical service manual, as I said in my earlier post the engine electrical is a separate document. Most likely because the electronics are the same regardless of engine displacement.
 
The paper clip isn't going to work on the 555.
I had an 0W------ 555 and it didn't need to be cleared on an overrev. If you pay attention you shouldn't be over revving
 
31 is the engine mechanical service manual, as I said in my earlier post the engine electrical is a separate document. Most likely because the electronics are the same regardless of engine displacement.
I ordered a used manual from EBay, noting that the manual for S/Ns prior to 300,000 applied to PCMs while I have ECM 5550204. Looking at the videos again, I saw Canadian mechanics using a software program called Mercury Marine Diagnostic System on a laptop to diagnose and clear codes. Somebody got charged for it I expect and the boat had been brought in for service. I'll check the S/N. On cars, codes light CELs and the car fails Emissions and it is brought in for service. The beep codes are accompanied by a variety of partial power reductions. It would be nice if they were all cleared in the next ignition cycle. Thanks again for the referral to the manual as that was my initial objective this morning.

The guy at Offshore, Dave_N, agrees with the Naysayers above and says the trick won't work for me: "Your engine has an ECM 555 controller. This trick will not work on PCM or ECM 555 systems. You will need a scan tool or smartcraft system display to read faults."
 
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2011 Sea Ray Sundancer 240. Bravo 3 engine. Been hitting a transient error and not having much luck finding root cause.

Boat runs fine at 4300rpm for 15-20min. Then, SmartCraft kicks in and reduces RPM. The error I receive is the following:
STBD System Fault 52 (I only have 1 engine), Engine Power Limited, Engine Guardian is Active, Power will be limited.

I've had my mechanic go over the engine and here are things that were done as part of getting the boat ready for the season:
1) Replaced impeller
2) Replaced oil sender/receiver
3) Replaced (new) lower unit

Any ideas on what this error "52" is? I'm beginning to think it may be a bad ECM.
 

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