5006461 EVINRUDE EXHAUST HOUSING, 40-50 HP

Table 1
Diagnostic Trouble Codes for the Cooling Fan Solenoid
J1939 Code Description Notes
977–5 Fan Drive State : Current Below Normal The Electronic Control Module (ECM) detects the following conditions:
A low current condition in the output from the ECM to the cooling fan solenoid.
There are no active 168 diagnostic codes.
The Alert lamp will come on. The ECM will log the diagnostic code.
This diagnostic code will detect a fault in the circuit for the cooling fan solenoid that is most likely to be an open circuit.
4212–5 Fan Drive Bypass Command Status: Current Below Normal
977–6 Fan Drive State : Current Above Normal The ECM detects the following conditions:
A high current condition in the output from the ECM to the cooling fan solenoid.
There are no active 168 diagnostic codes.
The Alert lamp will come on. The ECM will log the diagnostic code.
This diagnostic code will detect a fault in the circuit for the cooling fan solenoid. This problem is most likely to be caused by a high side short to ground or a low side short to power.
4212–6 Fan Drive Bypass Command Status: Current Above Normal Refer to the Electrical Schematic for the application.
Table 2
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Thoroughly inspect the P2/J2 ECM connectors and thoroughly inspect the connector for the fan drive assembly. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
B. Perform a 30 N (6.7 lb) pull test on each of the wires that are associated with the fan drive assembly.
Electrical connectors
Result: All connectors, pins, and sockets are correctly connected and the harness is free of corrosion, abrasion, and pinch points.
Proceed to Test Step 2.
Result: There is a fault in the connectors and/or the harness.
Repair: Repair the connectors or the harness and/or replace the connectors or the harness. Ensure that all the seals are correctly in place and ensure that the connectors are correctly connected.
Use the electronic service tool to clear all logged diagnostic codes and then verify that the repair eliminates the fault.
2. Check for Active Diagnostic Codes
A. Remove the electrical power from the ECM.
B. Verify that the solenoid connectors are free of debris and connected securely.
C. Connect the electronic service tool to the diagnostic connector.
D. Restore the electrical power to the ECM.
E. Select diagnostic tests on the electronic service tool.
F. Select the "Override Parameters" screen.
G. Activate the fan override.
H. Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes. Wait at least 30 seconds in order for the diagnostic code to become active.
I. Disable the fan override.
Active Diagnostic Codes
Result: No diagnostic codes are active.
The problem may have been related to a faulty connection in the harness. Carefully inspect the connectors and wiring. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Result: A 977–5 or 4212-5 code is active.
Proceed to Test Step 3.
Result: A 977–6 or 4212–6 code is active.
Proceed to Test Step 4.
3. Create a Short Circuit in the Harness at the Solenoid
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the fan drive assembly.
C. Fabricate a jumper wire that is long enough to create a short between the terminals of the connector for the fan drive assembly. Crimp connector pins to each end of the jumper wire.
D. Install the wire between the fan control terminal and the fan control return terminal on the harness connector for the fan drive assembly to create a short circuit.
E. Turn the keyswitch to the ON position. Wait for 10 seconds. Check for active diagnostic codes on the electronic service tool.
E. Activate the fan override.
F. Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes. Wait at least 30 seconds in order for the diagnostic code to become active.
Disable the fan override. Remove the jumper wire.
Short Circuit
Result: The 977–5 or 4212–5 code remains active with the jumper in place.
Proceed to Test Step 5.
Result: A 977–6 or 4212–6 code is active when the jumper wire is installed. A 977–5 or 4212–5 code is active when the jumper wire is removed.
Repair: Replace the fan drive assembly. Reset all active codes and clear all logged codes. Verify that the fault is resolved.
If the fault is still present, contact the Dealer Solutions Network (DSN).
4. Create an Open Circuit at the Solenoid
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the fan drive assembly.
C. Turn the keyswitch to the ON position. Wait for 10 seconds. Check for active diagnostic codes on the electronic service tool.
D. Activate the fan override.
E. Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes. Wait at least 30 seconds in order for the diagnostic code to become active.
F. Disable the fan override.
Open circuit
Result: A 977–6 or 4212–6 code was active before disconnecting the connector. A 977–5 or 4212–5 code became active after disconnecting the connector.
Repair: Replace the fan drive assembly. Reset all active codes and clear all logged codes. Verify that the fault is resolved.
If the fault is still present, contact the Dealer Solutions Network (DSN).
Result: A 977–6 or 4212–6 code remains active. There is a short circuit between the harness connector for the engine fan control solenoid and the ECM.
Proceed to Test Step 5.
5. Bypass the Wiring Harness
A. Turn the keyswitch to the OFF position.
B. Disconnect the P2 connector and the fan drive assembly connector.
C. Remove the wires for the solenoid control and solenoid return from the P2 connector. Refer to the electrical schematic for the application.
D. Remove the control and return wires from the connector for the fan drive assembly.
E. Fabricate two jumper wires that are long enough to reach from the ECM to the fan drive assembly connector.
F. Insert one end of a jumper into the solenoid control position on the P2 connector. Insert the other end of the jumper into socket 4 on the harness connector for the fan drive assembly.
G. Insert one end of a jumper into the solenoid return position on the P2 connector. Insert the other end of the jumper into socket