Tohatsu MD40B2 TLDI Troubleshooting
| Engine Model: Tohatsu MD40B2 |
| Engine Type: 2-stroke 3-cylinder gasoline outboard engine |
| Total Displacement: 42.5 cu.in (697 cc) |
| Rated Engine Power: 40 Hp (29.5 kW) at 5850 rpm |
| Fuel System: Two stroke low pressure direct injection (TLDI) |
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| Engine will not start or hard to start |
Empty gas tank - Add gasoline.
Improper fuel grade - Use correct fuel grade.
Air in the fuel lines - Bleed the fuel lines.
Spark plug wiring connection is damaged - Check the spark plug wire connection, repair or replace.
Damaged spark plug - Change spark plug as required.
Fuel filter is dirty - Replace or clean fuel filter.
Fuel lines are dirty - Fuel lines need to be cleaned.
Fuel pressure is low - Check low pressure fuel pump or check system for fuel leaks.
Low air pressure - Inspect air system for leaks.
Damaged electrical wire harness - Check electrical wire harness connections.
Defective ignition system - Check ignition components and replace if necessary.
Fuel feed pump is faulty - Install new fuel feed pump.
Fuel injector is clogged or malfunction - Replace or clean if necessary.
ECM failure - Replace ECM.
Reed valve is defective or worn - Replace reed valve as required.
| Engine starts and stops suddenly |
Defective spark plug - Install new spark plug.
Ignition coil is defective - Ignition coil must be replaced.
Faulty fuel pump - Replace fuel pump.
Fuel system clogging - Clean fuel system.
Fuel filter is clogged - Install new filter.
Defective ignition - Test ignition and replace failed parts.
Damaged spark plug - Replace spark plug.
Clogged or damaged fuel pump - Service or change fuel pump.
Low air pressure - Normalize air pressure.
Fuel lines are dirty - Fuel lines need to be cleaned.
Dirty fuel filter - Fuel filter needs changing.
Direct injector is faulty - Install new injector.
Engine is overloaded - Reduce the load.
Improper ignition timing - Set the ignition timing properly.
Thermostat failure - Replace thermostat.
Water pump is defective - Install new water pump.
Incorrect propeller selection - Replace propeller.
Damaged or improper size of propeller - Replace propeller.
Outboard motor is mounted too high or too low - Mount the motor as required.
Low octane fuel - Change fuel.
Engine is overloaded - Reduce engine load.
Incorrectly adjusted low idle speed - Test and adjust.
Clogged or defective fuel pump - Clean or change fuel pump.
Worn main bearings or crankshaft - Have bearings or crankshaft replaced.
Damaged piston rings or cylinder bore - Change defective parts.
Fuel pump is clogged or faulty - Clean or replace fuel pump.
Ignition system malfunction - Inspect ignition system and change failed components.
Worn powerhead parts - Defective components need to be replaced.
Low fuel pressure - Check system for fuel leaks or check low pressure fuel pump.
Low air pressure - Normalize air pressure.
Compression is insufficient - Normalize compression.
Fuel delivery problem - Check and repair.
Fuel regulator leaks - Repair leaks.
Dirty fuel filter - Change fuel filter.
Fuel injector is faulty or clogged - Clean or replace if necessary.
Manifold fuel leak - Repair leaks.
Propeller selection improperly - Install correct propeller.
Damaged or improper size of propeller - Have propeller repaired or replaced.
Incorrect outboard motor mounting height - Adjust the engine to correct transom height.
Trim angle is incorrect - Adjust trim angle.
Spark plug is defective or loose - Re-tighten or change the spark plug.
Worn piston, rings, or sleeve - Replace defective components as required.
Engine is overloaded - Reduce engine load.
Fuel injectors are damaged or dirty - Test fuel injectors and change if necessary.
| Excessive motor vibration |
Propeller bent or damaged - Have propeller repaired or replaced.
Propeller shaft damaged - Propeller shaft needs to be replaced.
Weeds in the propeller - Clean the propeller.
Motor mounting bolt is loose - Tighten bolt.
Steering pivot is loose or damaged - Tighten or replace.
Damaged or improper size of propeller - Replace propeller.
Damaged propeller shaft - Have propeller shaft replaced.
Weeds wraped around propeller - Clean the propeller.
Motor mounting bolt is loose - Tighten bolt.
| Trim motor is running but trim system cannot move up or down |
Oil insufficient - Check oil level and add oil as required.
Defective pump assembly - Check pump and change if required.
Leakage of manual drain valve - Valve need to be closed or changed.
Pump driveshaft or motor damaged - Change defective component.
| Trim cannot be fully up or down |
Pump assembly faulty - Replace pump.
Tilt ram piston ball is in wrong position - Service or repair.
Tilt ram piston O-ring is worn - Install new O-ring.
Low oil level - Check oil level and add oil as required.
Lower check valve not seating in port side trim ram - Install valve correctly.
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| Outboard Engines Technical Specifications |
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