3R0-02095-0 Tohatsu BOLT, 5-10

Illustration 1 g00897609
Rear view
Illustration 2 g00897197
Left view
Illustration 3 g00897221
Closed position
(1) Adjusting bolt (2) Thrust washer Width of groove in shaft for thrust washer ... 6.53 0.10 mm (0.2571 0.0039 inch)Thickness of thrust washer ... 6.00 0.05 mm (0.236 0.002 inch) (3) Locking nut (4) Plate (5) Bolt (6) Stop plate (7) Housing Bore in housing for shaft bearings ... 25.402 0.010 mm (1.0001 0.0004 inch)Outside diameter of shaft bearings ... 25.529 0.020 mm (1.0051 0.0008 inch) (8) Shaft (9) Choke plate (10) Bolt (11) Bearing Install the bearings so the lubrication fitting is in an accessible position.Lubricate the bearings with 5P-0960 Molybdenum Grease. (12) O-ring Lubricate the O-ring with 1U-6396 O-Ring Assembly Compound. (13) Bolt Apply 4C-5598 High Temperature Anti-Seize to the threads and to the face of the bolts. (14) Nut Torque for nuts ... 25 6 N m (18 4 lb ft) (15) Rod Distance between the center bores of the rod ends ... 121.6 mm (4.787 inch) (16) Clevis Apply 4C-4030 Thread Lock Compound to the threads. (17) Nut Torque for nuts ... 25 6 N m (18 4 lb ft) (18) Nut Torque for nut ... 200 20 N m (150 15 lb ft) (19) Rod Distance between the center bores of the rod ends ... 340.1 mm (13.389 inch) (20) Actuator (21) Inlet port (22) Outlet port (A) Angle Angle for the lever in the fully closed position ... 27 degrees (B) Angle Angle for the lever in the fully closed position ... 45 degrees (C) Angle Angle for the lever in the fully closed position ... 34 degreesUse the following procedure to assemble the air choke:
Assemble choke plate (9) to shaft (8). Loosely install bolts (10).
Install thrust washer (2) and tighten bolts (5).
To ensure that bolts (10) are properly seated in shaft (8), fully close choke plate (9) and tighten bolts (10).
Make sure that choke plate (9) is fully closed. Loosen locking nut (3) and turn adjusting bolt (1) until the bolt is seated against stop plate (6). Tighten the bolt for an additional 1/4 turn (90 degrees) and then tighten the locking nut.
Assemble the actuator with inlet port (21) in the upward position and with outlet port (22) in the downward position. Tighten nut (18) to the specified torque.
Apply 4C-4030 Thread Lock Compound to the threads of clevis (16).
Assemble rod (15). Provide equal engagement of the threads at both ends of the rod until the distance between the center bores of the rod ends is approximately the specified length.
Assemble rod (19). Provide equal engagement of the threads at both ends of the rod until the distance between the center bores of the rod ends is approximately the specified length.
For final adjustment of the linkage, ensure that the actuator does not try to force stop plate (6) past plate (4) when the choke plate is moved to the fully open position.
Fully extend the actuator. Make sure that the choke plate is in the fully open position and that stop plate (6) contacts plate (4).
Then reduce the length of rod (15) by 1/2 turn (180 degrees). This allows a clearance between stop plate (6) and plate (4).
Make sure that the choke plate can achieve the fully closed position. Tighten nuts (14) and nuts (17) to the specified torque.