3K9-03200-0 Tohatsu CARBURETOR ASSY

Table 1
Required Tools
Tool Part Number Part Description Qty
B 4C-5597 Anti-Seize Compound 1
Illustration 1 g01974473
Ensure that turbocharger (3) is clean and free from damage. Inspect the turbocharger for wear. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If any part of the turbocharger is worn or damaged, the complete turbocharger must be replaced.
Test wastegate actuator (22) for correct operation. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect". If any part of the wastegate actuator is worn or damaged, the complete turbocharger must be replaced.
Illustration 2 g01974333
Clean the gasket surface of exhaust manifold (18). If necessary, install studs (21) to turbocharger (3). Tighten the studs to a torque of 18 N m (160 lb in).
Install a new gasket (20) to studs (21).
Position turbocharger (3) onto the exhaust manifold and loosely install nuts (19). Note: Ensure that the turbocharger is correctly oriented.
Illustration 3 g02352967
Illustration 4 g02386497
Turbocharger tightening sequence viewed from the exhaust manifold.
Apply sufficient pressure in position (A) to ensure that the studs (21) are in the lowest position on manifold (18) and horizontal. Do not release the pressure from the turbocharger in Position (A) until nuts (19) have been tightened securely.
Tighten nuts (19) in the sequence shown in Illustration 4 to a torque of 44 N m (32 lb ft).
Illustration 5 g01974558
Illustration 6 g01973256
Remove plugs and caps from tube assemblies. Ensure that tube assembly (13) and tube assembly (17) are clean and free from damage. Replace any damaged components.
Position a new gasket (15) (not shown). Install bolts (8) to tube assembly (17). Tighten bolt (8) to a torque of 22 N m (195 lb in).
Remove the plug from oil inlet port (23). Lubricate the turbocharger bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor several times in order to lubricate the bearings.
Install a new sealing washer (14) to banjo bolt (12). Install the banjo bolt to tube assembly (13). Install the remaining new sealing washer (14) to banjo bolt (12).
Position tube assembly (13) onto turbocharger (3). Tighten banjo bolt (13) to a torque of 20 N m (177 lb in).
Illustration 7 g01973253
Use Tooling (B) to lubricate the bolt for V-band clamp (6). Position V-band clamp (6) onto elbow (7).
Position hose assembly (11) and elbow (7) onto the outlet of turbocharger (10) and turbocharger (3). Tighten the V-band clamp to a torque of 12 N m (106 lb in).
Tighten hose clamps (11) securely.
Ensure that elbow (1) is free from wear and damage. If necessary, replace the elbow that is worn or damaged.
Use Tooling (B) to lubricate the bolt for V-band clamp (2). Position V-band clamp (2) onto elbow (1).
Use Tooling (B) to lubricate the bolt for V-band clamp (9). Position V-band clamp (9) onto turbocharger (10).
Position elbow (1) onto turbocharger (3) and turbocharger (10).
Tighten V-band clamp (2) and V-band clamp (7) finger tight. Ensure that the V-band clamps are seated correctly onto the turbochargers.
Tighten V-band clamp (2) and V-band clamp (9) to a torque of 12 N m (106 lb in).
Connect hose assembly (4) to the wastegate actuator.
Connect hose assembly to air outlet (5) to turbocharger (3). Tighten the hose clamps securely.