9101E3-5835 Tohatsu BOLT

Table 1
Required Tools
Tool Part Number Part Description Qty
A 9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
B 230-6284 Timing Pin (Camshaft) 1
C 364-9107 Timing Pin
(Fuel Injection Pump) 1
D 136-4632 Timing Pin
(Crankshaft) 1
268-1966 Adapter 1
E 298-5564 T40 Torx Socket 1 Start By:
Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure.
Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.
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.Dispose of all fluids according to local regulations and mandates.
Note: Care must be taken in order to ensure that the fuel injection pump timing is not lost during the removal of the front gear group. Carefully follow the procedure in order to remove the gear group.
Illustration 1 g02485936
Remove plug (1) from the cylinder block. Remove O-ring seal (2) from the plug.
Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. Install Tooling (D) through Hole (W) in order to lock the crankshaft so that number one piston is at top dead center on the compression stroke.
Remove Tooling (D).
Use Tooling (A) in order to rotate the crankshaft in a clockwise direction and position the crankshaft at the safe position. Refer to System Operation, Testing and Adjusting, "Position the Valve Mechanism Before Maintenance Procedures" for the correct procedure.
Illustration 2 g03707478
Use Tooling (E) in order to loosen threaded inserts (4) on all rocker arms (3). Unscrew threaded inserts (4) on all rocker arms (3) until all valves are fully closed. Note: Ensure that ALL threaded inserts are fully unscrewed.
Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. Install Tooling (D) through Hole (W) in order to lock the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to Illustration 1.
Illustration 3 g03707479
Install Tooling (B) through Hole (X) in camshaft gear (5) into the front housing. Use Tooling (B) in order to lock the camshaft in the correct position. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.
Install Tooling (D) into Hole (W) in the cylinder block. Use Tooling (D) in order to lock the crankshaft in the correct position. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. Note: Do not use excessive force to install Tooling (D). Do not use Tooling (D) to hold the crankshaft during repairs.
Use Tooling (C) in order to lock the fuel injection pump gear in the correct position. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove" for the correct procedure.
Illustration 4 g03707480
Alignment of timing marks
Mark gear (5), gear (6), gear (7) and gear (8) in order to show alignment. Refer to Illustration 4. Note: Identification will ensure that the gears can be installed in the original alignment.
Remove camshaft gear (5). Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install" for the correct procedure.
Remove idler gear (6). Refer to Disassembly and Assembly, "Idler Gear - Remove and Install" for the correct procedure. Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 9U-7336 Housing 1
5P-7305 Engine Turning Tool