346-63201-0 Tohatsu BOLT, HANDLE A

Illustration 1 g00770585
Illustration 2 g00770189
Test Step 1. Inspect Electrical Connectors and Wiring.
Thoroughly inspect ECM vehicle harness connector J1/P1, the firewall bulkhead connector, or the wait to start lamp. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the wait to start lamp.Refer to Illustration 2.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the harness and wiring for abrasion and pinch points from the battery to the ECM.Expected Result:All connectors, pins and sockets should be completely coupled and/or inserted and the harness and wiring should be free of corrosion, abrasion or pinch points.Results:
OK - Proceed to Test Step 2.
Not OK - 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.STOPTest Step 2. Check for Normal Operation of the Wait to Start Lamp.
Connect ET. Access the configuration screen and ensure that the "Output #9" parameter is programmed to "Wait To Start Lamp". For OCT01 Software, ensure that "Wait to Start Lamp" is programmed to "J1/P1:31". Also, "Fast Idle Enabled Lamp" must be programmed to "J1/P1:21".
Turn the ignition key switch to the OFF position for ten seconds. Turn the ignition key switch to the ON position.
The wait to start lamp should illuminate for approximately two seconds when the key switch is turned on. If conditions require the air inlet heater to turn on, the wait to start lamp should remain illuminated until the air inlet heater turns off or the engine is started.Expected Result:The wait to start lamp turns on and the wait to start lamp turns off per the above description.Results:
Yes - The wait to start lamp appears to operating correctly at this time.STOP
No - Proceed to Test Step 3.Test Step 3. Test the Circuit for the Wait to Start Lamp
Illustration 3 g00770210
Vehicle harness connector P1
Disconnect ECM vehicle harness connector J1/P1.
Fabricate a jumper wire 100 mm (4 inch) long. Crimp a Deutsch pin to both ends of the wire.
Insert the jumper into terminal 31 of connector P1.
Connect the other end of the jumper wire to terminal 65 (−battery) of connector P1.
Turn the ignition key switch to the ON position.
While the lamp is being watched, insert the jumper wire and remove the jumper wire.Refer to Illustration 3.Expected Result:Result 1 The wait to start lamp turns on while the jumper is connected to both sockets. Also, the wait to start lamp turns off when the jumper is removed from one of the sockets.Result 2 The lamp does not turn on while the jumper is connected to both sockets.Result 3 The lamp will stay on while the ECM vehicle harness connector is disconnected.Results:
Result 1 - The wait to start lamp is functioning properly. Proceed to Test Step 4.
Result 2 - The lamp did not turn on. The vehicle's lamp circuit is not functioning properly. The lamp is probably burned out or there is a problem in the wiring from the cab to either the ECM or the +Battery connection. Repair the lamp circuit or send the vehicle to the OEM dealer for repairs.STOP
Result 3 - Repair: Perform the following diagnostic procedure:The circuit between the ECM and the lamp is shorted to chassis ground. Repair the circuit or send the vehicle to the OEM dealer for repairs.STOPTest Step 4. Check ECM Operation of Wait to Start Lamp.
Illustration 4 g00770221
ECM breakout T-connector
Disconnect ECM vehicle harness connector J1/P1.
Insert a breakout T between ECM vehicle harness connector J1 and ECM vehicle harness connector P1.
Connect one probe of the voltage test lamp to terminal 65 (-battery). Connect the other probe of the voltage test lamp to terminal 52 (unswitched +battery) of the breakout T.
The test lamp should turn on. If the test lamp does not turn on, either the test lamp is faulty or the wiring to the ECM is faulty. Continue with this step if the lamp turns on.
Leave the probe of the test lamp connected to terminal 52 (unswitched +battery).
Connect the other probe of the test lamp to terminal 31 (output 9) of the breakout T.Refer to Illustration 4.
Turn the ignition key switch to the OFF position.
Connect ET to the cab data link connector. Access the configuration screen and ensure that the "Output #9" parameter is programmed to "Wait To Start Lamp".
Turn the ignition key switch to the OFF position for ten seconds. Turn the ignition key switch to the ON position.
The wait to start lamp should illuminate for approximately two seconds when the key switch is turned on. If conditions require the air inlet heater to turn on, the wait to start lamp should remain illuminated until the air inlet heater turns off or the engine is started.Expected Result:The test lamp turns on and the test lamp turns off per the above description.Results:
Yes - The ECM is operating correctly. There is a problem in the vehicle wiring or the lamp.STOP
No - Repair: Temporarily connect a test ECM. Ensure that the "Output #9" parameter is programmed to "Wait To Start Lamp". Check the ECM operation of the PTO Switch ON Lamp when the test ECM is installed. If the problem is resolved with the test ECM, reconnect the suspect ECM. If the problem returns with the suspect ECM, replace the ECM.