30960-1010 Tohatsu HEAD, GEAR CASE

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 5P-7306 Housing 1
5P-7305 Engine Turning Tool 1
B 136-4632 Timing Pin (Crankshaft) 1
268-1966 Adapter 1
C 230-6284 Timing Pin (Camshaft) 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning 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 System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Inspect the bore in the front housing for damage. If the bore is damaged, replace the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove" for the correct procedure.
Illustration 1 g02791604
Install a new O-ring seal (19) to fuel injection pump (8).
Install new sealing washers (16) to bolts (17).
Carefully install fuel injection pump (8) to front housing (18). Note: The fuel injection pump should be supported by hand as the bolts are installed.
Install bolts (17) to fuel injection pump (8) hand tight.
Tighten bolts (17) to a torque of 22 N m (195 lb in).
Illustration 2 g02791603
Illustration 3 g02792516
Position bracket (14) onto the cylinder block and the fuel injection pump. Install bolt (15) to the cylinder block finger tight.
Install the nut and bolt (13) to fuel injection pump (8) finger tight.
Tighten bolts (15) to a torque of 44 N m (32 lb ft). Tighten the nut and bolt (13) to a torque of 22 N m (195 lb in). Note: Ensure that the fuel injection pump is not stressed as the bolts for the bracket are tightened.
Ensure that the No. 1 cylinder is at top dead center on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Fuel Injection Timing - Check". If necessary, use Tooling (A) in order to rotate the crankshaft so that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.
Use Tooling (C) in order to lock the camshaft in the correct position. Use Tooling (B) in order to lock the crankshaft in the correct position.
Install the fuel injection pump gear to fuel injection pump (8). Refer to Disassembly and Assembly, "Fuel Injection Pump Gear - Install".
Remove Tooling (C) and Tooling (B).
Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.
Install a new seal (10) (not shown) to tube assembly (9).
Connect tube assembly (9) to fuel injection pump (8) and the cylinder head.
Tighten tube nut (20) to a torque of 8 N m (71 lb in).
Tighten tube nut (21) to a torque of 6 N m (53 lb in).
Remove the plugs from fuel injection pump (8).
Remove the caps from plastic tube assembly (3), plastic tube assembly (4), and plastic tube assembly (6).
Connect plastic tube assembly (3), plastic tube assembly (4), and plastic tube assembly (4) to fuel injection pump (8).
Install plastic tube assembly (3), plastic tube assembly (5), and plastic tube assembly (6) to clips (5) and clip (7).
Connect the OEM harness assemblies to solenoid (11) and solenoid (12).
Illustration 4 g02791601
Loosen locking screw (1). Rotate spacer (2) in order to allow locking screw (1) to tighten against spacer (2). Tighten locking screw (1) to a torque of 12 N m (106 lb in). Note: Ensure that the fuel injection pump is in the unlocked position.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the ON position.
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure. End By:
Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure .