3F3-76219-0 Tohatsu KEY, MAIN SWITCH (NO.303)

Table 1
Diagnostic Codes
CDL Code Code Description Comments
3409-5 Engine Exhaust Manifold Bank #1 Flow Balance Valve Solenoid : Current Below Normal The Electronic Control Module (ECM) detects a low current in the circuit for the balance valve solenoid.
3409-6 Engine Exhaust Manifold Bank #1 Flow Balance Valve Solenoid : Current Above Normal The ECM detects a high current in the circuit for the balance valve solenoid. The balance valve actuator and balance valve solenoid are integral components. The valve is designed with a normally open position. As the solenoid is energized, the valve is closed. Air flow to the diaphragms of the balance valves at the turbochargers is restricted. The valve vents residual air pressure that is in the air lines to the atmosphere.In order to test the balance valve actuator, a test apparatus that consists of the following tooling will be required:
Table 2
Required Tooling
Quantity Part Number
1 215-2592 Wastegate Kit
1 65120 7/16"-20 JIC to hose barb
1 93215 9/16"-20 JIC to hose barb
Illustration 1 g02140483
Schematic for the balance valve solenoid
Table 3
Troubleshooting Test Steps Values Results
1. Check for Codes
A. Connect Cat® Electronic Technician (ET) to the service tool connector.
B. Determine if a code is active or logged.
Codes
Result: No codes are active for the balance valve solenoid at this time, but operation of the balance valve actuator is suspect.
Proceed to Test Step 2.
Result: A 3409-5 is active or logged. There is a low current in the circuit for the balance valve solenoid.
Proceed to Test Step 9.
Result: A 3409-6 is active or logged. There is a high current in the circuit for the balance valve solenoid.
Proceed to Test Step 8.
Illustration 2 g02139266
Inspection points for the balance valve air lines
Table 4
Troubleshooting Test Steps Values Results
2. Inspect the Air Lines from the Balance Valve Actuator to the Balance Valves at the Turbochargers
A. Inspect the air lines from the outlet of the balance valve actuator to the inlet of each of the balance valves. Check the lines for any signs of leakage.
Leakage
Result: The lines are not damaged. All of the line fittings are clean and tight.
Proceed to Test Step 3.
Result: Damage to the lines is discovered.
Repair: Repair the line or replace the line. Return the unit to service.
Verify that the repair eliminated the problem.
Illustration 3 g02139372
Inspection points for the balance valve linkage
Table 5
Troubleshooting Test Steps Values Results
3. Inspect the External Linkage for the Balance Valves at each Turbocharger
A. Inspect the balance valve linkage from each of the canisters to the housing. Also, inspect the connection point from the canister to the valve. Inspect the linkage for the following issues.
Dirt buildup
Rubbing
Damage
External Linkage
Result: The linkage is not damaged.
Proceed to Test Step 4.
Result: The linkage is damaged.
Repair: Replace the turbocharger. Return the unit to service.
If the problem is not resolved, proceed to Test Step 4.
Illustration 4 g02139379
(1) Pressurized air supply
(2) Pressure regulator
(3) Gate valve
(4) Pressure gauge
(5) Balance valve solenoid
(6) Exhaust balance valve
(7) Gate valve
Illustration 5 g02139660
Test apparatus that is fully assembled
Table 6
Troubleshooting Test Steps Values Results
4. Install the Test Apparatus and Check the System with Pressurized Air
A. Use the parts that are listed in Table 2 to assemble the test apparatus.
B. Connect the test apparatus between the inlet of the