3A1-63039-0 Tohatsu LONG HANDLE 0.8M

Illustration 1 g03153816
Rear view of engine
Illustration 2 g03153819
Cam gear bolt tightening sequence
Table 1
Item Qty Part Specification Description
1 1 230-6202 Idler Gear As Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
After installation, bore in the 224-9664 Bushing is 71.035 0.013 mm (2.7967 0.0005 inch).
Installation depth of the bushing is 2.6 0.5 mm (0.10 0.02 inch).
2 6 5B-0213 Bolt Torque to 55 10 N m (41 7 lb ft).
3 2 331-6188 Camshaft Gear As Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
With the number one piston in the top dead center position, align the timing marks. The mark on the camshaft gear must be in alignment with the mark in the rear housing.
4 12 6J-3913 Bolt Tighten bolt in the sequence 1, 4, 2, 5, 3, 6, 1, 4 as per Illustration 2 to 240 40 N m (177 30 lb ft).
5 1 245-3804 Bolt Torque to 55 10 N m (41 7 lb ft).
6 12 7K-6058 Bolt Torque to 135 20 N m (100 15 lb ft).
7 2 228-5814 Idler Gear As Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
8 1 226-6036 Idler Gear As Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
With the number one piston in the top dead center position, align the timing marks. The mark on the idler gear must be in alignment with the mark on the crankshaft gear (10).
After installation, bore in the 226-6052 Bushing is 88.090 0.013 mm (3.4681 0.0005 inch).
Installation depth of the bushing is 3.2 0.5 mm (0.13 0.02 inch).
9 4 1A-2029 Bolt Torque to 55 10 N m (41 7 lb ft).
10 1 228-5813 Crankshaft Gear As Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
Illustration 3 g03153822
Section A-A
Table 2
Item Qty Part Specification Description
11 1 224-1220 Plate Install the plate with the side marked "OUT" away from the gear face.
Thickness is 8.0 0.5 mm (0.31 0.02 inch).
12 1 185-1497 Idler Gear As Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
After installation, bore in the 224-9664 Bushing is 71.035 0.013 mm (2.7967 0.0005 inch).
Installation depth of the bushing is 2.6 0.5 mm (0.10 0.02 inch).
13 1 229-1663 Thrust Plate Install the thrust plate with the side marked "OUT" away from the gear face.
Thickness is 6.35 0.25 mm (0.250 0.010 inch).
14 1 6V-3319 O-Ring Seal Before assembly, lubricate the bore lightly with the lubricant that is being sealed.
Illustration 4 g03153825
Section B-B
Table 3
Item Qty Part Specification Description
15 2 5F-7403 Lockwasher Bend the tab on the lockwashers that aligns with the slot in the bearing locknut (16).
16 2 5F-7404 Bearing Locknut Torque to 406 68 N m (299 50 lb ft).
17 2 117-8801 O-Ring Seal Before assembly, lubricate the bore lightly with the lubricant that is being sealed.
18 2