9101E3-0612 Tohatsu BOLT

Illustration 1 g01065716
Schematic for the throttle actuator circuit for engines GZJ00001-00551.
Illustration 2 g06231453
Schematic for the throttle actuator circuit for engines GZJ00552-Up.
Test Step 1. Inspect the Electrical Connectors and Wiring
Remove the electrical power from the engine.Note: For the following steps, refer to Troubleshooting, "Electrical Connectors - Inspect".
Thoroughly inspect each of the following connectors:
J1/P1 connectors
J9/P9 connectors
Connectors on the throttle actuator
Check the torque of the allen head screw for the ECM connectors.
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the throttle actuator.
Illustration 3 g01065718
Right side view with the throttle actuator
Check the wiring for abrasion and for pinch points from the throttle actuator to the master ECM.Expected Result:All of the connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.Results:
OK - The components are in good condition with proper connections. Proceed to Test Step 2.
Not OK - The components are not in good condition and/or at least one connection is improper.Repair: Perform the necessary repairs and/or replace parts, if necessary. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem.STOPTest Step 2. Check for Diagnostic Codes
Connect Cat ET to the service tool connector on the terminal box.
Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode.
Use Cat ET in order to determine if one of the following diagnostic codes is active:
1440-9 Throttle Actuator : Abnormal Update Rate
1440-11 Throttle Actuator invalid
1440-12 Throttle Actuator : FailureExpected Result:None of the diagnostic codes are active.Results:
OK - None of the diagnostic codes are active. The communication between the master ECM and the throttle actuator appears to be OK at this time. However, diagnostic codes may be logged.Repair: If you are troubleshooting an intermittent problem, refer to Troubleshooting, "Electrical Connectors - Inspect".Terminating resistors must be connected to each end of the CAN data link. The terminating resistors improve the communication between the devices. If there is an intermittent diagnostic code for any of the devices that are connected to the CAN data link, be sure to check the terminating resistor that is inside the terminal box.The second terminating resistor is located internal to either the compressor bypass actuator or the fuel metering valve depending on the current engine configuration. Check that there is a jumper wire present at one of the following locations:
Turbocharger compressor bypass actuator terminals J and K
Raptor fuel metering valve terminals R and PMake repairs, when possible. Replace parts, if necessary.STOP
Not OK (Active 1440-9) - The master ECM has detected a problem with the communication between the master ECM and the throttle actuator. Proceed to Test Step 3.
Not OK (Active 1440-11) - There is an active 1440-11 diagnostic code. This code indicates a problem with the linkage of the throttle actuator.Repair: Set the engine control to the OFF/RESET position. Remove the electrical power from the engine. Move the throttle plate through the entire range of travel while you feel the motion. If the motion is sticky and/or rough, investigate the cause of the binding. Perform the necessary repairs.STOP
Not OK (Active 1440-12) - There is an active 1440-12 diagnostic code.Repair: The controller for the throttle actuator has detected an internal fault. Replace the actuator. Verify that the repair has eliminated the original problem.STOPTest Step 3. Check for Electrical Power at the Actuator
Illustration 4 g01234707
Locations for the voltage check at the junction box
Refer to Illustration 4. Measure the battery voltage at the junction box.
Disconnect the electrical connector from the actuator.
Illustration 5 g01233703
Locations for the voltage check at the harness connector for GZJ00001-00551.
Illustration 6 g06233845
Locations for the voltage check at the harness connector for GZJ00552-Up.
Measure the voltage between terminals N and P at the harness connector for GZJ00001-00551 and terminals Q and Z at t