9161F4-0645 Tohatsu BOLT

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-2322 Puller Assembly 1
5P-4170 Step Plate 1
B 5P-0944 Puller Group 1
5P-0941 Extractor 1
5P-0939 Extractor 1 Start By:
Remove the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove".
Remove the timing gear cover. Refer to Disassembly and Assembly, "Timing Gear Cover - Remove and Install".
Remove the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets - Remove and Install".
Remove the pistons and the connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Remove".
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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g00790969
Typical example
Check each bearing cap (1) for the location on the engine. Each bearing cap has an arrow which points toward the front of the engine and a number which gives the location of that bearing cap. Keep each bearing with the correct bearing cap.
Remove the bearing caps No. 2 through No. 6. Remove thrust plates from No. 4 upper bearing.
Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft. Remove No. 1 and No. 7 main bearing caps. Remove the crankshaft. The weight of the crankshaft is approximately 148 kg (326 lb).
Be careful not to damage the crankshaft journals when removing the crankshaft.
Illustration 2 g00790992
Remove crankshaft gear (2) with Tooling (A).
Remove the dowel and the pin with Tooling (B).
Put an identification mark on the upper half of the main bearing for proper location in the cylinder block. Remove main bearing upper halves.
Check the condition of the main bearings and crankshaft. Refer to Guideline for Reusable Parts, SEBF8009 and Visual Inspection of Crankshafts, SEBF8043.Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
C 8T-5096 Dial Indicator Group 1
D - LOCTITE Graphite-50 -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 3 g01424064
Install pin (5) in crankshaft (7).Maximum protrusion of pin (5) from the face of crankshaft (7) ... 6.4 0.5 mm (0.25 0.02 inch)
Install dowel (6) in crankshaft (7).The protrusion of dowel (6) from crankshaft (7) face. ... 4.1 0.5 mm (0.16 0.02 inch)
Illustration 4 g01424067
Raise the temperature of crankshaft gear (2) to a maximum temperature of 232 °C (450 °F). Install gear (2) on the crankshaft with groove (3) in alignment with the dowel.Note: Gear (2) must be installed on the crankshaft with the "V"timing mark toward the outside.
Clean the block and the upper main bearings.Note: Install the main bearings dry when clearance checks are made. Put clean engine oil on the upper main bearings and journals of the crankshaft.
Install the upper bearings in the cylinder block. Ensure that the tab in each bearing is in alignment with the notch in the cylinder block.
Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft and place the crankshaft into position in the block. The weight of the crankshaft is approximately 180 kg (400 lb).
Install the crankshaft with the