5032197 EVINRUDE RELAY, TNT, down

Illustration 1 g01194820
Schematic for the engine fan control solenoid
Illustration 2 g01141049
J1/P1 ECM connector (typical left side engine view)
Illustration 3 g01113249
P1 ECM connector
(P1-43) Engine fan control solenoid
(P1-51) Solenoid return
Table 1
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Wiring
A. Remove the electrical power from the ECM.
B. Thoroughly inspect the J1/P1 ECM connectors. Inspect all of the other connectors that are in the circuit for the engine fan control solenoid. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".
C. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
D. Check the allen head screw on each of the ECM connectors for the proper torque. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
E. Check the harness and the wiring for abrasion and for pinch points.
Electrical Connectors and Wiring
Result: The harness and wiring appear to be OK.
Proceed to Test Step 2.
Result: There is a problem in the connectors and/or wiring.
Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.
STOP
2. Check for Active Diagnostic Codes
A. Remove the electrical power from the ECM.
B. Connect Cat® ET to the service tool connector.
C. Restore the electrical power to the ECM.
D. Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes.
Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
E. Determine if the problem is related to an open circuit diagnostic code (05) or a short circuit diagnostic code (06).
Diagnostic Codes
Result: No diagnostic codes are active.
Repair: The problem may have been related to a faulty connection in the harness. Carefully inspect the connectors and wiring. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".
STOP
Result:A short circuit diagnostic code (06) is active at this time.
Proceed to Test Step 3.
Result: An open circuit diagnostic code (05) is active at this time.
Proceed to Test Step 4.
3. Disconnect the Connector for the Engine Fan Control Solenoid in Order to Create an Open Circuit
A. Remove the electrical power from the ECM.
B. Disconnect the connector for the engine fan control solenoid.
C. Restore the electrical power to the ECM.
D. Access the "Active Diagnostic Code" screen on Cat ET. Check for an active open circuit diagnostic code (05) for the engine fan control solenoid. Wait at least 30 seconds for activation of the diagnostic codes.
E. Remove the electrical power from the ECM.
Diagnostic Codes
Result: A short circuit diagnostic code (06) was active before disconnecting the connector. An open circuit diagnostic code (05) became active after disconnecting the connector.
Repair: Temporarily connect a new engine fan control solenoid to the harness, but do not install the new engine fan control solenoid. Verify that there are no active diagnostic codes for the engine fan control solenoid. If there are no active diagnostic codes for the engine fan control solenoid, permanently install the new engine fan control solenoid. Clear any logged diagnostic codes.
STOP
Result: There is a short circuit between the harness connector for the engine fan control solenoid and the ECM. Leave the connector disconnected.
Proceed to Test Step 5.
4. Create a Short at the Connector for the Engine Fan Control Solenoid
A. Remove the electrical power from the ECM.
B. Fabricate a jumper wire that is long enough to short the terminals of the connector for the engine fan control solenoid. Crimp connector pins to each end of the jumper wire.
C. Install the jumper wire between terminal 1 (engine fan control solenoid) and terminal 2 (solenoid return) on the harness side of the connector.
D. Restore the electrical power to the ECM.
E. Access the "Active Diagnostic Code" screen on Cat ET. Check for an active short circuit diagnostic code (06) for the engine fan control solenoid. Wait at least 30 seconds for activation of the diagnostic codes.
F. Remove the jumper wire.
G. Remove the electrical power from the ECM.
Diagnostic Codes
Result: A short circuit diagnostic code (06) is active when the jumper wire is installed. An open circuit diagnostic code (05) is active when the jumper wire is removed.
Repair: The engine harness and the ECM are OK. Temporarily connect a new engine fan control solenoid to the harness, but do not install the new engine fan control solenoid. Verify that there are no active diagnostic codes for the engine fan control solenoid. If there are no active diagnostic codes for the engine fan control solenoid, permanently install the new engine fan control solenoid. Clear any logged diagnostic codes.
STOP
Result: The open circuit diagnostic code (05) remains active with the jumper in place.
The open circuit is between the ECM and the connector for the engine fan control solenoid. There may be a problem with the ECM. Proceed to Test Step 5.
5. Check the Operation of the ECM
A. Disconnect the J1/P1 ECM connector.
B. Fabricate two jumper wires that are long enough to connect terminals of the ECM connector. Crimp connector sockets to one end of each of the jumper wires.
C. Remove the wire from terminal location P1-43 (engine fan control solenoid) at the ECM connector. Install a jumper wire into this terminal location.
D. Remove the wire from terminal location P1-51 (digital return) at the ECM connector. Install a jumper wire into this terminal location.
E. Connect the J1/P1 ECM connector.
F. Create an open at the ECM:
1. Restore the electrical power to the ECM.
Note: In order to ensure that an open circuit condition exists, do not allow the loose ends of the jumper wires to connect.
2. Monitor the "Active Diagnostic Code" screen on Cat ET. Wait at least 30 seconds for activation of the code.
G. Create a short at the ECM:
1. Short the jumper wires at the ECM connector.
2. M