3V1-06023-0 Tohatsu ALTERNATOR

Recommended Actions
Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.
Diagnostic Codes
Use one of the following methods to check for active diagnostic codes:
The electronic service tool
The display on the control panelElectronic Service Tool
Connect the electronic service tool to the diagnostic connector.
Check for active diagnostic codes on the electronic service tool.
Investigate any active codes before continuing with this procedure. Refer to Troubleshooting, "Troubleshooting with a Diagnostic Code".Display on the Control PanelNote: The following procedure is only applicable if the application is equipped with a display on the control panel.
Check the display on the control panel for active diagnostic codes.
Troubleshoot any active codes before continuing with this procedure. Refer to Troubleshooting, "Troubleshooting with a Diagnostic Code".ECM Parameters
Use the electronic service tool to make sure that the FLS and FTS parameters have been correctly entered.
Use the electronic service tool to ensure that the correct mode is selected on the Mode Selector Switch.
Use the electronic service tool to verify that the correct engine rating has been provided.
Use the electronic service tool to verify the maximum engine speed limit.
Ensure that the repairs have restored the expected performance.
If the repairs have not eliminated the faults, proceed to "Electrical Connectors".Electrical Connectors
Turn the start switch to the ON position.
Use the electronic service tool to verify that the intake manifold pressure is zero 0.5 kPa (zero 0.070 psi). Check the 5 VDC sensor supply for the intake manifold pressure. Refer to Troubleshooting, "5 VDC Sensor Supply Circuit - Test".
Use the electronic service tool to verify the throttle position status.
Run the engine until the speed is equal to the maximum no-load speed.
Use the electronic service tool to make sure that the throttle is set to reach the maximum no-load speed.
If the maximum no-load speed cannot be obtained refer to Troubleshooting, "Throttle Switch Circuit - Test" and Troubleshooting, "Mode Selection Circuit - Test".
If the engine speed is erratic refer to Troubleshooting, "Analog Throttle Position Sensor Circuit - Test" or Troubleshooting, "Digital Throttle Position Sensor Circuit - Test".
If the fault has not been eliminated, proceed to "Air Intake and Exhaust System".Air Intake and Exhaust System
Check the air filter restriction indicator, if equipped.
Ensure that the air filter is clean and serviceable.
Check the air intake and the exhaust system for the following defects:
Blockages
Restrictions
Damage to the air intake and exhaust lines and hoses
Make all necessary repairs to the engine.
If the fault has not been eliminated, proceed to "Valve Lash".Valve Lash
Check the valve lash. Refer to Systems Operation, Testing, and Adjusting, "Engine Valve Lash - Inspect".
If any repair does not eliminate the fault, proceed to "Turbochargers".Turbochargers
Note: The turbochargers that are installed on the engine are nonserviceable items. If any mechanical fault exists, then the faulty turbocharger must be replaced.
Ensure that the mounting bolts for the turbochargers are tight.
Check that the oil drains for the turbochargers are not blocked or restricted.
Check that the compressor housings for the turbochargers are free of dirt and debris. Make sure that the housings are not damaged.
Check that the turbine housings for the turbochargers are free of dirt and debris. Make sure that the housings are not damaged.
Check that the turbine blades rotate freely in the turbochargers.
Ensure that the wastegate on the high-pressure turbocharger is adjusted correctly. Refer to Systems Operation, Testing, and Adjusting, "Turbocharger - Inspect". If the wastegate actuator is faulty, replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".
If necessary, replace the faulty turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".
Check that the repairs have eliminated the faults.
If the fault has not been eliminated, proceed to "Fuel Supply".Fuel Supply
Visually check the fuel tank for fuel. The fuel gauge may be faulty.
Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
Check the primary filter/water separator for water in the fuel.
Check for fuel supply lines that are restricted.
Check that the low-pressure fuel lines are tight and secured properly.
Replace the in-line fuel strainer that is installed upstream of the Electric Fuel Lift Pump (EFLP).
Check that the Electric Fuel Lift Pump (EFLP) is operating. If the EFLP is suspect, refer to Troubleshooting, "Fuel Pump Relay Circuit - Test".
Replace the primary fuel filter and the secondary fuel filter. Refer to the Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element - Replace".
Check the diesel fuel for contamination. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test".
Check for air in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Air in Fuel - Test".
Ensure that the fuel system has been primed. Refer to Systems Operation, Testing, and Adjusting, "Fuel System - Prime".
Turn the keyswitch to the OFF position and then disconnect the electrical connector from the EFLP.
With the keyswitch in the ON position, measure the voltage at the harness connector for the EFLP. The voltage must be between 20 VDC and 28 VDC. If the voltage is below 20 VDC, investigate the cause. Refer to Troubleshooting, "Fuel Pump Relay Circuit - Test".
Turn the keyswitch to the OFF position and then reconnect the electrical connector to the EFLP.
If a repair has been performed to rectify a low supply voltage to the EFLP, attempt to start the engine. If the engine does not start, continue with this procedure.Note: Before performing the following fuel system tests, the engine must be stopped for a minimum of 30 minutes.Note: When performing the following fuel system tests, the Electric Fuel Lift Pump (EFLP) will only operate for 2 minutes unless the engine is running. If necessary, cycle the keyswitch in order to reactivate the pump.
Use the following procedure to check the flow from the Transfer Pump Inlet Regulator (TPIR):