916189-0865 Tohatsu BOLT

The following background information is related to this procedure:EGR ValveThe EGR valve is used to control the amount of exhaust gas which is recirculated into the intake manifold.The amount of exhaust gas that is required is calculated by the software that is contained in the ECM. The EGR valve is controlled by a PWM signal from the ECM.Intake Throttle ValveThe intake throttle valve is used to increase the exhaust gas temperature to aid the regeneration process.
Illustration 1 g03728445
Schematic diagram for the motorized valves
Illustration 2 g03728447
Typical view of the pin locations on the 62-pin engine interface connector for the motorized valves
(29) EGR valve PWM signal
(30) EGR valve return
(33) EGR valve position sensor 5 VDC supply
(34) EGR valve position sensor signal
(35) EGR valve position sensor ground
(37) Intake throttle valve PWM signal
(38) Intake throttle valve return
(41) Intake throttle valve position sensor 5 VDC supply
(42) Intake throttle valve position sensor signal
(43) Intake throttle valve position sensor ground
Illustration 3 g03616849
Typical view of the pin locations on the J2 connector for the motorized valves.
(8) Intake throttle valve position sensor 5 VDC supply
(9) EGR valve position sensor 5 VDC supply
(24) EGR valve position sensor ground
(34) Intake throttle valve return
(35) EGR valve return
(37) Intake throttle valve position sensor ground
(39) EGR valve position sensor signal
(49) Intake throttle valve PWM signal
(50) EGR valve PWM signal
(53) Engine intake throttle valve position sensor signal
Table 2
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Thoroughly inspect connectors for the motorized valves. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
B. Thoroughly inspect the P2/J2 ECM connector and the 62-pin engine interface connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
C. Perform a 30 N (6.7 lb) pull test on each of the wires that are associated with the motorized valves.
Damaged wire or connector
Result: A damaged wire or damaged connector was found.
Repair: Repair the damaged wire or the damaged connector.
Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.
Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points.
Proceed to Test Step 2.
2. Check for Diagnostic Codes
A. Turn the keyswitch to the OFF position.
B. Connect the electronic service tool to the diagnostic connector.
C. Turn the keyswitch to the ON position.
D. Monitor the electronic service tool for active diagnostic codes and/or logged diagnostic codes.
Diagnostic codes
Result: A -7 diagnostic code is active or recently logged for one or more of the motorized valves
Proceed to Test Step 3.
Result: A -5 diagnostic code is active or recently logged for one or more of the motorized valves.
Proceed to Test Step 5.
Result: A -6 diagnostic code is active or recently logged for one or more of the motorized valves.
Proceed to Test Step 8.
3. Measure the Sensor Supply Voltage at the Valve Connector
A. Turn the keyswitch to the OFF position.
B. Disconnect the suspect valve from the engine harness.
C. Turn the keyswitch to the ON position.
D. Measure the voltage at the harness connector for the valve from the 5 V supply terminal of the position sensor to the sensor ground terminal.
4.9 v to 5.1 V
Result: The measured voltage is within the expected range.
Repair: Install a replacement for the suspect valve. Refer to Disassembly and Assembly for more information.
Note: If the EGR valve is replaced, use the electronic service tool to perform the "EGR Valve Learn Reset".
Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.
Result: The measured voltage is not within the expected range.
Reconnect the valve connector. Proceed to Test Step 4.
4. Measure the Sensor Supply Voltage at the 62-Pin Connector
A. Turn the keyswitch to the OFF position.
B. Disconnect the 62-pin connector.
C. Turn the keyswitch to the ON position.
D. Measure the voltage at the 62-pin connector on the harness between the engine and the ECM from the 5 VDC sensor supply terminal for the suspect valve to the sensor ground terminal .
4.9 V to 5.1 V
Result: The measured voltage is within the expected range.
The fault is in the 5 VDC supply wire or the ground wire between the suspect valve and the 62-pin connector.
Repair: Replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The measured voltage is not within the expected range.
The fault is in the 5 VDC su