921503-0438 Tohatsu SCREW

Table 2
Required Tooling for the Procedure
373-4609 Spark Tester
Table 3
Troubleshooting Test Steps Values Results
1. Determine the Code
A. Connect Cat® Electronic Technician (ET) to the service tool connector.
B. Use the "Aftertreatment #1 Ignition Transformer Primary Override" on Cat ET to turn on the ARD ignition system. The ARD ignition system must operate for 20 seconds in order for a diagnostic trouble code to become active. securely.
C. Determine the code that is present.
Diagnostic code
Result: A 2465-5, 2465-6, 3484-5 or 3484-6 code is present.
Proceed to Test Step 5.
Result: A 3180-5 or 4265-5 code is present or a diagnostic code is not present.
Proceed to Test Step 2.
2. Inspect the Ignition Wire
A. Visually inspect the ignition wire between the ignition coil and the ARD combustion head. Look for the following problems:
1. Loose connections or damaged connectors
2. Moisture on the connectors or the ignition wire
3. Damage to the ignition wire that is caused by excessive heat
4. Damage to the ignition wire that is caused by chafing
5. Improper routing of the ignition wire
6. Damaged insulation on the ignition wire
B. Push the boot on each end of the ignition wire. This tests whether the clip inside the boot is connected to the spark plug and to the ignition coil. There should be a "click" when you push the boot onto either part. If you felt a "click", the clip inside the boot was not previously connected.
Damaged wire
Result: The ignition wire is not damaged.
Proceed to Test Step 3.
Result: The ignition wire is damaged.
Repair: Replace the ignition wire.
Proceed to Test Step 8.
Illustration 1 g02388518
(1) 373-4609 Spark Tester
Illustration 2 g02309455
Table 4
Troubleshooting Test Steps Values Results
3. Check for Spark at the Coil Output, Using the Spark Indicator
A. Assemble the 373-4609 Spark Tester as shown in Illustration 1.
Ensure that the alligator clip is secured to a good ground source.
B. Install the spark indicator as shown in Illustration 2.
C. Use the "Aftertreatment #1 Ignition Transformer Primary Override" on Cat ET to turn ON the ARD ignition system. Check for spark in the spark indicator.
Spark
Result: Spark is present in the indicator.
Proceed to Test Step 4.
Result: Spark is not present in the indicator.
Repair: Replace the ignition coil. Inspect the connector terminals. If terminal damage/erosion is found, repair the ground from the coil housing to the chassis. Also, inspect the ground wire from the coil to the ARD head.
Proceed to Test Step 8.
Illustration 3 g02478839
Table 5
Troubleshooting Test Steps Values Results
4. Check for Spark to the Spark Plug
A. Assemble the 373-4609 Spark Tester as shown in Illustration 3.
B. Install the spark plug indicator between the spark plug and the end of the spark plug wire.
C. Use the "Aftertreatment #1 Ignition Transformer Primary Override" on Cat ET to turn ON the ARD ignition system. Check for spark in the spark indicator.
Spark
Result: Spark is present in the indicator.
Repair: Replace the spark plug.
Proceed to Test Step 8.
Result: Spark is not present in the indicator.
Repair: Replace the ignition wire.
Proceed to Test Step 8.
Illustration 4 g01395281
Information for the ignition circuit.
Table 6
Troubleshooting Test Steps Values Results
5. Replace the Ignition Wire
A. Replace the ignition wire between the ignition coil and the ARD combustion head.
B. Use the "Aftertreatment #1 Ignition Transformer Primary Override" on Cat ET to turn on the ARD ignition system.
Ignition Wire
Result: The