3T9S87802-0 Tohatsu DECAL SET

Illustration 1 g00744368Test Step 1. INSPECT ELECTRICAL CONNECTORS AND WIRING
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Verify that no circuit breakers are tripped.
Turn the Engine Control Switch (ECS) to the OFF/RESET position.
Turn the circuit breaker for the battery to the OFF position.
Thoroughly inspect ECM connector J2/P2 and unit injector connector J91/P91. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Check the harness and wiring for abrasion and for pinch points from the injectors to the ECM. Expected Result:All connectors, pins, and sockets are completely inserted and coupled. The harness and wiring are free of corrosion, of abrasion, and of pinch points.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Repair the circuit. 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 FOR LOGGED DIAGNOSTIC CODES
Connect the Caterpillar Electronic Technician (ET) to the service tool connector.
Turn the circuit breaker for the battery to the ON position.
Turn the ECS to the STOP position.
Observe the diagnostic codes on Cat ET. Expected Result:One or more of the following diagnostic codes have been logged:
1-05 "Injector Cylinder 1 open circuit" through 6-05 "Injector Cylinder 6 open circuit"
1-06 "Injector Cylinder 1 short" through 6-06 "Injector Cylinder 6 short"Results:
OK - Diagnostic codes that are associated with the injectors have been logged. Proceed to Test Step 3.
Not OK - Proceed to Test Step 4.Test Step 3. PERFORM THE INJECTOR SOLENOID TEST
Illustration 2 g00663576
"Injector Solenoid Test" screen in Cat ET
Note: This test will help the service technician verify that the ECM can fire the injector solenoids. Do not try to manually crank the engine during this test. The ECM will terminate the Injector Solenoid Test.
Start the engine and allow the engine to reach normal operating temperatures.
Turn the ECS to the OFF/RESET position.
Connect Cat ET to the service tool connector.
Turn the ECS to the STOP position.
Use "Diagnostic Tests" on Cat ET to initiate the "Injector Solenoid Test".
As each solenoid is energized by the ECM an audible click can be heard at the valve mechanism cover. Listen for a click at each valve mechanism cover. There will be a momentary delay between each one. A black square will appear over the cylinder number on Cat ET when the cylinder is being fired. Note: Repeat the Injector Solenoid Test a few times in order to verify that the ECM is energizing each solenoid.Expected Result:All cylinders indicate "OK".Results:
OK - There is not an electronic problem with the injectors at this time.STOP
Not OK - Repair: Note the cylinders that indicate "OPEN" and/or "SHORT".Proceed to Test Step 5.Test Step 4. PERFORM THE CYLINDER CUTOUT TEST
Illustration 3 g00663575
"Automated Cylinder Cutout Test" screen in Cat ET
Engine power is reduced when a properly functioning cylinder is cut out. Make sure that you will not damage auxiliary or driven equipment if the engine power is suddenly reduced.
Turn the circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET position.
Verify that the ECM connector J2/P2 and the injector connectors J91/P91 are properly connected.
Turn the circuit breaker for the battery to the ON position.
Start the engine.
Allow the engine to warm up to normal operating temperature 77 °C (171 °F).
Apply a load to the engine.
After the engine is warmed to operating temperature, access the "Cylinder Cutout Test" by accessing the following display screens in order:
"Diagnostics"
"Diagnostic Tests"
"Cylinder Cutout Test"
Set the engine speed to 1800 rpm.
Select the start button at the bottom of the screen for the "Cylinder Cutout Test".
Select the "4 Cylinder Cutout Test" which is the default test.
Follow the instructions that are provided in the "Cylinder Cutout Test". The "Cylinder Cutout Test" is interactive so the procedure is guided to the finish. Note: The "Manual Cylinder Cutout Test" is also available. Access the manual test by selecting the "Change" button on the Cat ET screen for the "Cylinder Cutout Test". The "4 Cylinder Cutout Test" is the recommended starting procedure. The automated tests run twice collecting data. The two sets of data are analyzed and an "OK" or "NOT OK" result is displayed.Note: Check for a difference in the sound, feel, or power of the engine as each cylinder is cut out. The amount of change should be similar for all of the properly operating cylinders. The amount of change should be minimal for a weak cylinder or a misfiring cylinder.Expected Result:All cylinders indicate "OK" on Cat ET.Results:
OK - The test indicates that all of the cylinders are operating correctly.Repair: If the engine is misfiring or if the engine has low power, refer to Troubleshooting, "Engine Misfires, Runs Rough or Is Unstable" and Troubleshooting, "Low Power/Poor or No Response to Throttle".STOP
Not OK - There was no change in the sound, feel, or power of the engine as one of the cylinder's was cut out. Proceed to Test Step 5.Test Step 5. CHECK THE ENGINE HARNESS FROM P2 TO P91 FOR SHORT CIRCUITS
Turn the ECS to the OFF/RESET position.
Disconnect unit injector connector J91/P91.
Turn the ECS to the STOP position.
Perform the "Injector Solenoid Test" at least two times. Expected Result:All cylinders indicate "Open".Results:
OK - Proceed to Test Step 6.
Not OK - All injectors do not indicate "Open".Repair: Note the cylinders that indicate a short circuit.Proceed to Test Step 7.Test Step 6. CHECK THE ENGINE HARNESS FROM P2 TO P91 FOR AN OPEN CIRCUIT