33470-1221 Tohatsu CAP, FUEL GAUGE

Problem 1.
Oil At The ExhaustProbable Cause
Too Much Oil In The Valve Compartment Look at both ends of the rocker arm shaft. Be sure that there is a plug in each end.
Worn Valve Guides Reconditioning of the cylinder head is needed.
Worn Piston Rings Inspect and install new parts as needed.
Defective Seal In Turbocharger Reconditioning of the turbocharger is needed.
Plugged Air Cleaner Element Replace air cleaner element.Problem 2.
Exhaust Temperature Is Too HighProbable Cause
Air Inlet Or Exhaust System Has A Restriction Remove restriction.
Wrong Fuel Injection Timing Adjust the timing.
Air Inlet System Has A Leak Check pressure in inlet system. Find leaks and correct.
Exhaust System Has A Leak Find cause of exhaust leak and correct.Restriction Of Air Inlet And Exhaust
If there is a restriction of the air inlet, or of the exhaust system, horsepower, and engine efficiency will be reduced. Air flow through the air cleaner must not have a restriction (negative pressure difference measurement between atmospheric air and air that has gone through air cleaner) of more than 762 mm (30 inch of H2O).Back pressure from the exhaust (pressure difference measurement between turbocharger exhaust at the outlet elbow and atmospheric air) must not be more than 685 mm (27 inch of H2O).Measurement Of Exhaust Temperatures
Use the 1U-8865 Infrared Thermometer to check exhaust temperature. Instructions for the test procedures can be found in Special Instruction SEHS8149. These instructions are included with the infrared thermometer.Measurement Of Pressure In Inlet Manifold
The efficiency of an engine can be checked by a comparison of the pressure in the inlet manifold with the information given in TMI Web*. This test is used when there is a decrease of horsepower from the engine, yet there is no real sign of a problem with the engine.The correct pressure for the inlet manifold is given in TMI Web*. Development of this information is done with these conditions:
99 kPa (29.4 inch mercury)
29°C (85°F) outside air temperature.
35 API rated fuelAny change from these conditions can change the pressure in the inlet manifold. Outside air that has higher temperature and lower barometric pressure than given above will cause a lower horsepower and a lower inlet manifold pressure measurement than given in TMI Web*. Outside air that has a lower temperature and a higher barometric pressure will cause higher horsepower and a higher inlet manifold pressure measurement.A difference in fuel rating will also change horsepower and the pressure in the inlet manifold. If the fuel is rated above 35 API, pressure in the inlet manifold can be less than given in the TMI Web*. If the fuel is rated below 35 API, the pressure in the inlet manifold can be more than given in TMI Web*. Be sure that the air inlet and exhaust do not have a restriction when making a check of pressure in the inlet manifold.
Illustration 1 g03094479
Plug location for test
(A) 1/8 inch pipe plug Note: This location will yield a slightly higher pressure. The higher pressure is due to the air being heated in the cylinder head.
Illustration 2 g00294866
1U-5470 Engine Pressure Group
Use the 1U5470 Engine Pressure Group to check the inlet pressure.Remove plug (A) on to cylinder head to measure inlet manifold pressure.This tool group has a gauge to read pressure in the inlet manifold. Special Instruction Form No. SEHS8907 is with the tool group and gives instructions for use.*In TMI Web use :
48W47603 for only HWH00101
48W47605 for only HWH00102
48W47615 for only HWH00103
0K4262 test specAftercooler - Test
Table 1
Tools Needed
Part Number Part Name Quantity
1U-5470 Engine Pressure Group 1
FT-1984 Aftercooler Testing Group 1
FT-1438 Aftercooler Gp (Dynamometer Test) 1 Visual Inspection
Inspect the following parts at each oil change:
Air lines
Hoses
Gasket joints
Pressurized air can cause personal injury. When pressurized air is used for cleaning, wear a protective face shield, protective clothing, and protective shoes.
Ensure that the constant torque hose clamps are tightened to the correct torque. Check the welded joints for cracks. Ensure that the brackets are tightened in the correct positions. Ensure that the brackets are in good condition. Use compressed air to clean any debris or any dust from the aftercooler core assembly. Inspect the fins in the aftercooler core for the following conditions:
Damage
Debris
CorrosionUse a stainless steel brush to remove any corrosion.Note: When parts of the air-to-air aftercooler system are repaired or replaced, a leak test is recommended.Inlet Manifold Pressure
Normal inlet manifold pressure with high exhaust temperature can be caused by blockage of the fins of the aftercooler core. Clean the fins of the aftercooler core. Refer to "Visual Inspection" under this topic for the cleaning procedure.Low inlet manifold pressure and high exhaust manifold temperature can be caused by any of the following conditions:Plugged air cleaner - Clean the air cleaner or replace the air cleaner, as required. Refer to the Operation and Maintenance Manual, "Engine Air Cleaner Element - Clean/Replace".Blockage in the air lines - Blockage in the air lines between the air cleaner and the turbocharger must be removed.Aftercooler core leakage - Aftercooler core leakage should be pressure tested. Refer to "Aftercooler Core Leakage" under this topic for the testing procedure.Inlet manifold leak - An inlet manifold leak can be caused by the following conditions: loose fittings and plugs, missing fittings and plugs, damaged fittings and plugs and leaking inlet manifold gasket.Aftercooler Core Leakage