398S63000-1 Tohatsu HANDLE KIT

Table 1
Required Tools
Tool Part Number Part Description Qty
A 207-5034 Stud Tensioner Tool Gp 1
8T-3035 Hydraulic Line 1
8T-0820 Hydraulic Pressure Gauge 1
3S-6224 Electric Hydraulic Pump
(115 Volt 50/50 Hz) 1
8S-8033 Electric Hydraulic Pump
(230 Volt 50/60 Hz) 1
9U-6600 Hand Hydraulic Pump 1 Start By:
Remove the crankcase access covers.
Remove the oil filler and the oil level gauge.
Remove the centrifugal oil filters.
Remove the crankcase explosion relief valves. Refer to Disassembly and Assembly, "Crankcase Explosion Relief Valves - Remove and Install".
Remove the crankshaft rear gear. Refer to Disassembly and Assembly, "Crankshaft Rear Gear - Remove and Install".
Remove the crankshaft front gear. Refer to Disassembly and Assembly, "Crankshaft Front Gear - Remove and Install".
Remove the pistons and connecting rods. Refer to Disassembly and Assembly, "Piston and Connecting Rods - Remove".
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
There is no set procedure for removing the crankshaft. Each engine installation will require a specific procedure to be followed. In order to determine the best procedure for the removal of the crankshaft in your application, consult the 3600 Customer Service Group at 765-448-5980.Note: There are no special tools for lifting and supporting the 3600 Engine.Each engine has been designed so that the crankshaft can be removed without removing the front timing gear housing. Use the procedure that follows.
Illustration 1 g00586197
Failure to securely block or support the engine properly could allow engine movement that may result in injury or death. Always use blocks, jack stands, or engine support stands in order to support the engine prior to the removal of the crankshaft.
Illustration 2 g00586199
Remove the engine mounting bolts (1) and the saddle bolts (2) from each side of the engine.
Illustration 3 g00586202
Remove the crankcase access covers. Place two steel beams (3) 152 × 152 mm (6 × 6 inch) through the crankcase housing near the ends of the engine block.
Illustration 4 g00586204
Place hard wood blocks under the steel beams that are through the crankcase housing. Use a suitable lifting device in order to raise the engine until there is enough room for the removal of the crankshaft. Illustration 4 shows a clearance (X) of 1067 mm (42 inch). The clearance (X) is from the top of the base to the bottom of the steel beam under the engine. The weight of the engine is approximately 26354 kg (58100 lb)for the G3612 Engines. The weight for the G3616 Engines is approximately 29892 kg (65900 lb).
Illustration 5 g00586207
Place two steel beams 152 × 152 mm (6 × 6 inch) under the engine for support.
Use jacks in order to remove the oil pan from the engine. The weight of the oil pan is approximately 600 kg (1323 lb).
Never support a marine engine on hard wood blocks or steel beams. Vessel movement could cause engine movement. This may result in personal injury or death. Engine blocking for marine applications should only be done while the vessel is in drydock.
Place the tensioner in position under the rear main bearing cap.
Put the sleeve in position over the nuts. Install the wrench into one of the holes in the nut.
Raise the tensioner until the tensioner is against the reaction sleeve.
Install the adapter nuts. Tighten the nuts by using a 12 inch ratchet. After the nuts are tight, the nuts should be loosened 1 1/2 turns.
Before you operate the pump, ensure that all connections are secure. Ensure that all hoses are in good condition. Oil escaping under high pressure can cause personal injury.
Run the pump until a pressure of 62600 to 67400 kPa (9080 to 9776 psi)is registered on the gauge. This will put tension on the studs so that the nuts can be loosened.
Use the wrench in order to loosen each nut until the nut makes contact with the adapter nut. The nut should then be turned 90 degrees in the opposite direction.
Slowly release the hydraulic pressure.