910103-0865 Tohatsu BOLT

Table 1
Diagnostic Trouble Codes for the Electrical Power Supply
J1939 Code CDL Code Code Description
(code descriptions may vary) Comments
168-3 168-3 Electrical System Voltage : Voltage Above Normal The ECM detects voltage that is above the acceptable value.
168-4 168-4 Electrical System Voltage : Voltage Below Normal The ECM detects voltage that is below the acceptable value.
3216-5 3002-5 Aftertreatment 1 Intake NOx : Current Below Normal The ECM detects current that is below the acceptable value
3216-6 3002-6 Aftertreatment 1 Intake NOx : Current Above Normal The ECM detects current that is above the acceptable value
3226-5 3609-5 Aftertreatment 1 Outlet NOx : Current Below Normal The ECM detects current that is below the acceptable value
3226-6 3609-6 Aftertreatment 1 Outlet NOx : Current Above Normal The ECM detects current that is above the acceptable value
5758-11 3621-11 Engine Exhaust NOx Level Sensor Power Supply: Other Failure Mode The ECM detects voltage that is outside the acceptable value.
5759-11 3619-11 Aftertreatment #1 Outlet#1 NOx Level Sensor Power Supply: Other Failure Mode The ECM detects voltage that is outside the acceptable value. The engine ECM requires the keyswitch to be in the ON position to maintain communications with the electronic service tool.
Illustration 1 g03811196
Illustration 2 g03712263
Schematic for the NOx sensor power supply circuit
Illustration 3 g03421240
Pin locations on the P1 connector for the power supply circuit
(14) NOx sensor return
(57) SCR inlet NOx sensor power
(65) SCR outlet NOx sensor power
(69) Keyswitch input
(81) Battery -
(82) Battery -
(83) Battery -
(84) Battery +
(85) Battery +
(86) Battery +Complete the procedure in the order in which the steps are listed.
Table 2
Troubleshooting Test Steps Value Results
1. Inspect Electrical Connectors and Wiring
A. Ensure that the battery disconnect switch is in the CLOSED position.
B. Thoroughly inspect all connectors associated with the electrical power supplies.
C. Check all fuses.
D. Perform a 45 N (10 lb) pull test on each of the wires in the connectors associated with the electrical power supplies.
E. Check all the wiring associated with the electrical power supplies for abrasions and pinch points.
Damaged wire or connector. Blown fuse.
Result: A damaged wire or damaged connector was not found. The fuses are OK.
Proceed to Test Step 2.
Result: A damaged wire or damaged connector was found. A blown fuse was found.
Repair: Repair the damaged wire or the damaged connector. Replace all blown fuses.
Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.
2. Check the Charging Circuit
A. Check the charging circuit. Refer to Systems Operation, Testing and Adjusting, "Charging System - Test".
Charging circuit
Result: The charging system is OK.
Proceed to Test Step 3.
Result: The charging system is not OK. There is a fault in the charging system.
Repair: Make the necessary repairs.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
3. Load Test the Batteries
A. Use a suitable battery load tester to test the batteries. Refer to Systems Operation, Testing and Adjusting, "Battery - Test" for the correct procedure.
Load test
Result: The batteries pass the load test.
Proceed to Test Step 4.
Result: The batteries do not pass the load test.
Repair: Recharge or replace the faulty batteries.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
4. Check for Active Diagnostic Codes
A. Establish communication between the electronic service tool and the ECM. Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Check the "Active Diagnostics" screen on the electronic service tool.
Diagnostic code
Result: A 168-X diagnostic code is active.
Proceed to Table 3, "Troubleshooting Procedure for the Engine ECM Power Supply".
Result: A 5758-11, 3621-11,5759-11, 3619-11, 3216-X, 3002-X, 3226-X, or 3609-X diagnostic code is active.
Proceed to Table 4, "Troubleshooting Procedure for the NOx Sensor Power Supplies".
Table 3
Troubleshooting Procedure for the Engine ECM Power Supply
Troubleshooting Test Steps Value Results
1. Check the Voltage at the Ignition Keyswitch Input
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the ignition keyswitch.
C. Measure the voltage at the battery supply input to the ignition keyswitch.
Battery voltage
Result: The measured voltage is equal to battery voltage.
Reconnect the connector for the ignition keyswitch. Proceed to Test Step 2.
Result: The measured voltage is not equal to battery voltage.
Repair: Replace the wiring between the battery and the input to the ignition keyswitch.
Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.
2. Check the Keyswitch Signal Voltage
A. Turn the keyswitch to the OFF position.
B. Disconnect the P1 connector from the ECM.
C. Turn the keyswitch to the ON position. Do not attempt to start the engine.
D. Measure the voltage between P1:69 and a suitable ground.
Battery voltage
Result: The measured voltage is equal to battery voltage.
Proceed to Test Step 4.
Result: The measured voltage is not equal to battery voltage.
Proceed to Te