3C7B02300-0 Tohatsu EXHAUST COVER, OUTER

Table 1
Required Tools
Tool Part Number Part Description Qty
A 8B-7548 Push-Puller Tool Group 1
8B-7559 Adapter 2
8H-0684 Ratchet Wrench 1
8B-7561 Step Plate 3
B 138-7573 Link Bracket 2
C 169-5464 Quick Cure Primer -
D - Guide Bolts
5/8 - 11 NC by 8 inch 2
E -(1) Loctite 5127 -
(1) EAMEStart By:
Remove the starting motors.
Remove the engine oil pan (rear).
If the exhaust elbow is attached to the flywheel housing, remove the exhaust elbow and remove the bracket for the exhaust elbow.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Use the timing pins to properly time the engine. Refer to Testing and Adjusting, "Camshaft Timing". Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston".
Remove the crankshaft rear seal and the wear sleeve. Refer to Disassembly and Assembly, "Crankshaft Rear Seal and Wear Sleeve - Remove".
Remove the camshaft covers and gaskets.
Remove the bolts and plates from the camshafts.
Illustration 1 g00912881
Use Tooling (A) in order to remove camshaft drive gears (1).
Illustration 2 g00912883
Install Tooling (B) into flywheel housing (2). Attach a suitable lifting device to Tooling (B). The weight of flywheel housing (2) is approximately 251 kg (553 lb).
Remove the bolts and remove flywheel housing (2) and the gasket.
After removing flywheel housing (2), clean the mating surface of the cylinder block and the mating surface of the flywheel housing with Tooling (C). If necessary, use a gasket scraper and a solvent in order to remove any residual gasket material. Both mating surfaces must be clean, dry, and free of any oil before installation. Installation Procedure
Note: Refer to Engine News, 27, March 2006, "Sealing and Installing the Flywheel Housing" for more information.
Ensure that the mating surface of the flywheel housing and the engine block are clean. Both mating surfaces must be clean, dry, and free of any oil before Tooling (E) is applied.
Illustration 3 g01259519
Apply a 6.0 mm (0.25 inch) bead of Tooling (E) to the mating surface of the flywheel housing. Refer to Illustration 3.
Install Tooling (D) into the cylinder block.
Illustration 4 g00912883
Install Tooling (B) onto flywheel housing (2). Attach a suitable lifting device to Tooling (B). The weight of flywheel housing (2) is approximately 251 kg (553 lb).
Lift flywheel housing (2) into position onto Tooling (D). Note: For the correct positions of the bolts, see Illustration 5 or Illustration 6.
Install the bolts and the hard washers that secure flywheel housing (2) to the cylinder block. Remove Tooling (D) and install the remaining bolts and the remaining hard washers.
Illustration 5 g01259521
(A) 1/2 - NC
(B) 1/2 - NC
(C) 1/2 - NC
(D) 1/2 - NC
(E) 1/2 - NC
(F) 5/8 - NC
Illustration 6 g01259551
(G) 1/2 - NC
(H) 1/2 - NC
(I) 1/2 - NC
(J) 5/8 - NC
(K) 5/8 - NC
(L) 5/8 - NC
Tighten the bolts in flywheel housing (2) evenly. Tighten the 1/2 - NC bolts to a torque of 135 20 N m (100 15 lb ft). Tighten the 5/8 - NC bolts to a torque of 270 40 N m (200 30 lb ft). The torque for plugs (3) is 70 15 N m (50 11 lb ft).
Install the crankshaft rear seal and the wear sleeve. Refer to Disassembly and Assembly, "Crankshaft Rear Seal and Wear Sleeve - Install".
Place the camshaft timing pins in position. Place the timing bolt in the flywheel with the No. 1 piston at the top center position on the compression stroke.