910113-5616 Tohatsu BOLT

Table 1
Required Tools
Tool Part Number Part Description Qty
B - Scotch Brite 1
C 1U-5718 Vacuum Pump 1
169-7372 Bottle Assembly 1
4C-4057 Clear Plastic Tubing
7.92 mm (0.312 inch) OD 1
4C-4055 Clear Plastic Tubing
6.35 mm (0.250 inch) OD -
D 457-1623 Reamer 1
E 4C-6161 Tube Brush 1
F 9U-6862 Tapered Brush 1
G 4C-6774 Vacuum Gun Kit 1
H 4C-5027 Tap Wrench 1
J 276-7018 Plug/Cap Kit 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Evacuate as much fuel and oil as possible from the cylinder head before installing the unit injector. Several evacuations may be necessary. Use Tooling (C) to remove the fuel and oil from the cylinder.Note: Tooling (F) is available to clean loose material from the sleeve bore and the cylinder.
Clean the carbon from the sleeve, the sleeve bore, and the end of the unit injector. Clean the carbon from the seal area that is inside the cylinder head. A fine grade of Tooling (B) is preferred. Clean the carbon from the cylinder head. If the sleeve of the unit injector has been removed, use Tooling (D) to remove only carbon from the surface of the sleeve. If the sleeve of the unit injector is installed, use Tooling (E) to clean the carbon deposit from the inside of the sleeve.The following procedure is the preferred method of cleaning the sleeve bore.Place a 38 mm (1.5 inch) square piece of Scotch Brite material on the end of Tooling (F). Twist Tooling (F) with Tooling (H) against the lower surface of the sleeve bore.The surface should be cleaned until the surface is smooth and shiny. The entire sleeve bore should be cleaned to remove any loose carbon particles.Note: Tooling (G) is available to clean loose material from the sleeve bore and the cylinder.
The correct procedures and tooling specifications must always be used. Failure to follow any of the procedures may result in damage, malfunction, or possible engine failure.
Illustration 1 g01355602Note: Replace the O-ring seals on the injector.
Install O-ring seal (9) and O-ring seal (10) on unit injector (4). Lubricate O-ring seal (9), O-ring seal (10), and the sleeve bore of the unit injector sparingly with clean engine oil.
Record the serial number for the injector and the injector confirmation code. When you install a new unit injector, the E-Trim value must be programmed into the Engine Control Module. For more information, refer to Troubleshooting, "Injector Trim File - Install".
Illustration 2 g02161415
Illustration 3 g01264293Note: Verify quill tube (1) is positioned out of the bore enough to see O-ring seal (2). This action will ensure that the injector does not contact the quill tube during installation.
Place unit injector (4) into the bore. Make sure that the key (7) for the unit injector fits into slot (8) in the cylinder head.
Illustration 4 g02161316Note: Use new socket head bolt (5).
Position unit injector clamp (6) with the label "C9" in the up position. Install socket head bolt (5) into unit injector clamp (6). Tighten socket head bolt (5) to a torque of 28 3 N m (21 2 lb ft) to secure unit injector (4).
Illustration 5 g02161166
Connect harness assembly (3) to the unit injector.
Illustration 6 g01355441
Illustration 7 g01355608Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal.Note: The quill tube can be reused if it stays with the same injector. If a new injector is installed, replace the quill tube with a new quill tube.
If the O-ring was damaged, perform Step 8a and Step 8b.