910103-0820 Tohatsu BOLT

Illustration 1 g01136767
Schematic for ECM battery circuit
The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere.
Test Step 1. Inspect the Electrical Connectors and the Wiring
Turn the keyswitch to the OFF position.
Illustration 2 g01136776
Top engine view (1) J1/P1 ECM connector (2) P3 Customer connector
Thoroughly inspect connectors (1) and (2). Also inspect the connections for the battery to the ECM. Inspect the connections from the keyswitch to the ECM. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Inspect the following components for damage, corrosion, and incorrect attachment:
Battery posts
Alternator
Breaker
Engine ground
Illustration 3 g01136801
P1 terminals that are associated with the electrical power supply (P1-2) Remote shutdown (P1-4) Unswitched +Battery (P1-5) −Battery (P1-6) Unswitched +Battery (P1-11) −Battery (P1-23) Switched +Battery (keyswitch)
Illustration 4 g01136795
J3 and P3 terminals that are associated with the electrical power supply (1) Unswitched +Battery (2) Unswitched +Battery (26) Switched +Battery (keyswitch) (27) Remote shutdown
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the electrical power supply.
Check the allen head screw on the ECM connector for the proper torque. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and wiring for abrasions and for pinch points from the battery to the ECM. Also, check the harness and wiring for abrasions and for pinch points from the keyswitch to the ECM.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring are free of corrosion, of abrasion, and of pinch points.Results:
OK - The connectors and wiring are in good repair. Proceed to Test Step 2.
Not OK - There is a problem with the connectors 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. Verify that the repair eliminates the problem.STOPTest Step 2. Check Battery Voltage at the ECM
Disconnect the J1/P1 ECM connector.
Turn the keyswitch to the ON position.
Measure the voltage between P1-4 Unswitched +Battery and P1-5 -Battery.
Measure the voltage between P1-6 Unswitched +Battery and P1-11 -Battery.
Measure the voltage between P1-23 Switched +Battery (keyswitch) and P1-5 -Battery.Expected Result:The measured voltage is between 22.0 VDC and 27.0 VDC with no suspected intermittent problems at this time.Results:
OK - The ECM is receiving the correct voltage.Repair: If an intermittent condition is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - The battery voltage is not within specifications. Proceed to Test Step 3.
Not OK - An intermittent voltage or no voltage is measured. Proceed to Test Step 4.
Not OK - The voltage at the keyswitch is not within specifications.Repair: Trace the wiring for the keyswitch from the ECM through the keyswitch circuit to the batteries. Find the problem and repair the problem. Check the circuit protection for the circuit and for the wiring. Verify that the repairs eliminate the problem.STOPTest Step 3. Check the Batteries
Measure no-load battery voltage at the battery posts.
Load test the batteries. Use the 4C-4911 Battery Load Tester. Refer to Special Instruction, SEHS9249, "Use of 4C-4911 Battery Load Tester for 6, 8 and 12 Volt Lead Acid Batteries" and Special Instruction, SEHS7633, "Battery Test Procedure".Expected Result:The batteries pass the load test. The measured voltage is the minimum specification for a 24V system.Results:
OK - The batteries are OK.Repair: Check the wiring between the batteries and the ECM for shorts.Check the connectors between the batteries and the ECM for moisture and/or corrosion.Repair the wiring and/or the connectors. Verify that the repair eliminates the problem.STOP
Not OK - The battery voltage is low or the battery did not pass the load test.Repair: Recharge or replace the faulty batteries. Verify that the repair eliminates the problem.STOPTest Step 4. Use the Bypass Harness for the Electronic Service Tool to Bypass the Engine Wiring
Batteries give off flammable fumes which can explode.To avoid injury or death, do not strike a match, cause a spark, or smoke in the vicinity of a battery.