921503-5612 Tohatsu SCREW

Illustration 1 g01021696
Typical exampleTest Step 1. Check for Connector Damage.
Turn the circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and for pinch points.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion or of pinch points.Results:
OK - The connectors and wiring are okay. Proceed to Test Step 2.
Not OK - The connectors and/or wiring are not okay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 2. Check for Output Voltage to the Prelube Motor.
Turn the circuit breaker for the battery to the ON position.
Turn the ECS to the OFF/RESET position.
Connect one lead of a voltmeter to the −Battery terminal.
Connect the other lead of the voltmeter to wire C465-OR on terminal 2 of the prelube switch.
Turn the ECS to the START position.
Monitor the voltage on the voltmeter.
Turn the ECS to the STOP position.Expected Result:The voltage is 24 3 VDC.Results:
OK - The voltage is 24 3 VDC. Proceed to Test Step 7.
Not OK - The voltage is not 24 3 VDC. Proceed to Test Step 3.Test Step 3. Check for Output Voltage to the Prelube Switch.
Leave one lead of the voltmeter on the −Battery terminal.
Connect the other lead of the voltmeter to wire 118-GN on terminal 4 of the prelube switch.
Turn the ECS to the START position.
Monitor the voltage on the voltmeter.
Turn the ECS to the STOP position.Expected Result:The voltage is 24 3 VDC.Results:
OK - The voltage is 24 3 VDC.Repair: Verify that 24 3 VDC is present on terminal 1 of the prelube switch. If 24 3 VDC is not present on terminal 1, check the wiring and breakers between the battery and the prelube switch. Refer to Illustration 1 as a reference.Verify that wire 200-BK has continuity to the −Battery terminal. If wire 200-BK is okay and voltage is present on terminal 4, replace the prelube switch.STOP
Not OK - The voltage is not 24 3 VDC. Proceed to Test Step 4.Test Step 4. Check the Voltage from the Prelube Relay.
Leave one lead of the voltmeter on the −Battery terminal.
Connect the other lead of the voltmeter to wire 118-GN on terminal 30 of the prelube relay.
Turn the ECS to the START position.
Monitor the voltage on the voltmeter.
Turn the ECS to the STOP position.Expected Result:The voltage is 24 3 VDC.Results:
OK - The voltage is 24 3 VDC.Repair: Repair the wire 118-GN between the prelube switch and terminal 30 of the prelube relay.STOP
Not OK - The voltage is not 24 3 VDC. Proceed to Test Step 5.Test Step 5. Check the Voltage to the ECM from the Coil of the Prelube Relay.
Turn the ECS in the OFF/RESET position.
Remove wire F705-PK from terminal 86 of the prelube relay.
Connect one lead of the voltmeter on terminal 86 of the prelube relay.
Connect the other lead of the voltmeter to wire F705-PK that was removed from terminal 86 of the prelube relay.
Turn the ECS in the START position.
Monitor the voltage on the voltmeter.Expected Result:The voltage is 24 3 VDC.Results:
OK - The voltage is 24 3 VDC.Repair: Verify that 24 3 VDC is present on terminal 87 of the prelube relay. If 24 3 VDC is present on terminal 87, replace the prelube relay.STOP
Not OK - The voltage is not 24 3 VDC. Proceed to Test Step 6.Test Step 6. Check the Sinking Driver for the Prelube Relay.
Turn the ECS to the OFF/RESET position.
Disconnect ECM connector J1/P1.
Remove wire F705-PK from ECM connector P1-21. Install a jumper wire that has a pin on one end into P1-21.
Reconnect ECM connector J1/P1.
Connect one lead of a voltmeter to the jumper wire in P1-21 and the other lead to +Battery.
Turn the ECS to the START position.
Monitor the voltage on the voltmeter.
Turn the ECS to the OFF/RESET position.
Remove all jumpers and replace all wires.Expected Result:The voltage is 24 3 VDC.Results:
OK - The voltage is 24 3 VDC.Repair: Repair the wire F705-Pk between the prelube relay and ECM connector P1-21.STOP
Not OK - The voltage is not 24 3 VDC.Repair: Replace the ECM. Refer to the diagnostic procedure Troubleshooting, "Replacing the ECM".STOPTest Step 7. Check the Operation of the Prelube Motor.
Turn the circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET position.
Connect one side of a suitable piece of 10 AWG wire to the +Battery terminal.
For one second, connect the other end of the wire to the positive terminal of the prelube motor.Expected Result:The prelube motor starts while the wire is connected to the positive terminal.Results:
OK - The prelube motor starts. There is a problem in the wiring harness.Repair: Inspect the connectors and the wiring between the positive terminal of the prelube motor and pin 2 of the prelube switch.STOP
Not OK - The prelube motor did not start. The problem appears to be in the prelube motor.Repair: Temporarily replace the prelube motor with a new prelube motor. If the problem is no longer present, reinstall the old prelube motor. If the problem returns, replace the prelube motor.STOP