3T5B01031-0 Tohatsu CAP, THERMOSTAT

Table 1
Required Tools
Tool Part Number Part Description Qty
A 491-1265 Capping Kit 1 Start By:
Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install" for the correct procedure.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training.Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information.Refer to Systems Operation, Testing and Adjusting Manual, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
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: Put identification marks on electrical connectors and hoses for installation purposes. Plug all hose assemblies and tube assemblies. That helps to prevent fluid loss and plugging helps to keep contaminants from entering the system.
Ensure that the fuel supply to the OFF position.
Ensure that the battery disconnect switch to the OFF position.
Illustration 1 g03817041
Depress clip (7) and remove harness assembly .Place harness away from engine.
Reposition clip (1) on hose (8).
Remove banjo bolts (4) and sealing washers (3). Use Tooling (A) to plug or cap all open ports.
Remove leak off pipe (5) from engine and from hose (8). Remove sealing washer (2). Discard all old sealing washers. Use Tooling (A) to plug or cap all open ports.
Illustration 2 g03817407
Remove bolt (10) and washers (11). Remove clamp (12) and remove injectors (9). Repeat the procedure in order to remove the remaining fuel injections.
Illustration 3 g03817429
Remove O-ring seal (13) and sealing washer (14) from injector (9). Install Tooling (A) to the tip of the fuel injector nozzle. Discard used O-ring seals and sealing washers. Install Fuel Injector
All plugs and caps must be remain in position until the component is about to be installed
Illustration 4 g03817429
Install new O ring seal (13) onto injector (9).
Install new sealing washer (14) into the cylinder head.
Ensure that the orifices in the cylinder head for the fuel injectors are clean and free from debris.
Illustration 5 g03817407
Install the fuel injectors into the cylinder head. Install fuel injector (9). Install clamp (12) and install bolt (10) with washer (11).
Tighten bolts (10) to a torque of 26 N m (230 lb in).
Illustration 6 g03817041
Install leak off pipe (5) into hose (8) and place into position on the fuel injectors.
Install new sealing washer (2) and new sealing washers (3). Install banjo bolts (4) finger tight. Tighten the banjo bolts to a torque of 13 N m (115 lb in). Repeat the procedure on the remaining fuel injectors.
Position clip (1) on hose (8).
Install harness (6) onto fuel injectors. End By:
Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install" for the correct procedure.