910121-5614 Tohatsu BOLT

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g00741697
Disconnect the battery terminals.
Drain the cooling system. If the engine uses diesel engine antifreeze/coolant, refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change". If the engine uses extended life coolant, refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".
Illustration 2 g00741695
Remove bottom hose (10) and coolant overflow hose (6) from expansion tank (16) .
Loosen two plastic nuts (2) that fasten the vent tubes to the expansion tank.
Remove long vent tube (4) and short vent tube (3) from expansion tank (16) .Note: The vent tubes cannot be removed until the expansion tank is moved toward the front of the engine. Refer to Illustration 3.
Illustration 3 g00741696
Illustration 4 g00741625
Remove three bolts (15) and washers (14) from the engine. The six rubber bushings (13) and spacers (12) should remain with the expansion tank.
Remove expansion tank (16) from the engine.Note: If water outlet manifold (5) is removed, the gasket must be replaced. No sealant is used on the gasket for the water outlet manifold.Installation Procedure
Illustration 5 g00741697
Note: The bolt at the bottom of expansion tank (16) is 10 mm (0.39 inch) shorter than the two bolts at the top of the expansion tank. The bolt at the bottom of the expansion tank is threaded into a long nut (9) which is retained by stud (7). Ensure that stud (7) and long nut (9) are tight before the bolt is installed.
Inspect the expansion tank. Flush out the expansion tank with clean water in order to remove any debris. Clean the external surfaces of the expansion tank. Clean the fastener, the rubber bushings, and the bottom hose. If the six rubber bushings are damaged, replace the rubber bushings. If bottom hose (10) is damaged, replace the bottom hose. Check the expansion tank for cracks or for leaks. Check the seal of filler cap (1). Replace the filler cap if the seal is damaged.
If water outlet manifold (5) has been removed, install a new gasket. Do not use sealant on the gasket.
Ensure that stud (7), washer (8), and long nut (9) are in the correct position. Ensure that the stud, the washer, and the long nut are fully tightened.
Illustration 6 g00741625
Ensure that spacers (12) are installed into three rubber bushings (13) correctly. Install washers (14) onto bolts (15). Install three bolts (15). Ensure that rubber bushings (11) are installed on the back of the expansion tank. Tighten three bolts (15) .
Illustration 7 g00741695
Install long vent tube (4) and short vent tube (3). Install the short vent tube at 45° to the horizontal (17). Tighten two plastic nuts (2) by hand. Do not use a wrench.
Install bottom hose (10) and tighten the hose clamps.
Install coolant overflow hose (6) .
Fill the cooling system. If the engine uses diesel engine antifreeze/coolant, refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change". If the engine uses extended life coolant, refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".
Connect the battery terminals. Operate the engine in order to check for leakage of coolant.