3R0-77071-0 Tohatsu CYLINDER PIN UPPER

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Liner Projection Components (1) Bolt (2) Washer (3) Washer (4) Spacer plate (5) Block (6) Cylinder liner
Table 1
Needed Components    
Item     Part Number     Description     Quantity For One Cylinder     Quantity For Six Cylinders    
1     7H-3598     Bolt     6     26    
2     8F-1484     Washer     6     12    
3     7K-1977     Washer     6     12    
7     7X-0564     Washer     6     14    
8     126-1454     Washer     6     14    Note: The 7K-1977 Washer and the 126-1454 Washer are made of a fabric material. These washers are a disposable item. You may wish to order more washers than the amount that is indicated.
Illustration 2 g00533882
Install a new spacer plate gasket and a clean spacer plate.
Install the cylinder liners in the cylinder block without seals or bands.
Install the washers.
Install all bolts or the six bolts around the liner.Torque for bolts ... 95 N m (70 lb ft)
Use the 8T-0455 Liner Projection Tool Group to measure the liner projection at "A", "B", "C" and "D".
Record measurements for each cylinder.
Add the four readings for each cylinder. Divide the sum by four in order to find the average.
Table 2
Specifications    
Liner Projection    
0.025 to 0.152 mm (0.0010 to 0.0060 inch)    
Maximum Variation In Each Liner    
0.051 mm (0.0020 inch)    
Maximum Average Variation Between Adjacent Liners    
0.051 mm (0.0020 inch)    
Maximum Variation Between All Liners    
0.102 mm (0.0040 inch)    Note: If the liner projection changes around the liner, turn the liner to a new position within the bore. If the liner projection is not within specifications, move the liner to a different bore. Inspect the top face of the cylinder block. A thinner spacer plate should be installed if the liner projection measurements are below the specifications. The spacer plate should also be installed if the liner projection measurements are low within a range. These plates are 0.076 mm (0.0030 inch) thinner than the regular plate. The plates will increase the liner projection. This will increase the fire ring crush. Use these spacer plates to compensate for low liner projections that are less than the 0.076 mm (0.0030 inch). Use these spacer plates if the inspection of the top deck reveals no measurable damage directly under the liner flanges but the average liner projection is less than 0.076 mm (0.0030 inch).Do not exceed the maximum liner projection of 0.152 mm (0.006 inch). The excessive liner projection will contribute to cracking of the liner flange.When the liner projection is correct, put a temporary mark on the liner and the spacer plate. Set the liners aside.Note: Refer to Disassembly and Assembly, "Cylinder Liner - Install" for the correct final installation procedure for the cylinder liners.When the engine is ready for final assembly, the following items must be lubricated before installation.
O-ring seals
cylinder block
upper filler bandNote: Apply liquid soap and/or clean engine oil immediately before assembly. Avoid applying the liquid soap and/or clean engine oil to the seals too early. The seals may swell. This will cause the seals to be pinched underneath the liners during the liner installation.