30900-0040 Tohatsu PISTON 0.5MM O/S

Table 1
Required Tools
Tool Part Number Part Description Qty
A 388-1289 Capping Kit 1
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.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Turn the battery disconnect switch to the OFF position.
Turn the fuel supply to the OFF position.
Drain the secondary filter. Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.
Illustration 1 g03011036
Make temporary identification marks on plastic tube assembly (1) and plastic tube assembly (2) in order to show the correct position of the plastic tube assemblies.
Place a suitable container below the fuel filter base in order to catch any fuel that might be spilled.
Disconnect plastic tube assembly (1) and plastic tube assembly (2) from fuel filter base (3).
Use Tooling (A) in order to plug plastic tube assembly (1) and plastic tube assembly (2)
Use Tooling (A) in order to cap the connection on fuel filter base (3).
Slide locking tab in to the unlock position. Disconnect harness assembly (5) from fuel temperature sensor (4).
Illustration 2 g03011037
Remove cannister (8) from fuel filter base (3). Remove secondary filter (7). Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.
Remove nuts (6) from fuel filter base (3). Remove the fuel filter base from the mounting bracket. Note: Do not disassemble the fuel filter base.
Illustration 3 g03011038
If necessary, follow Step 1.c through Step 12.c in order to remove the bracket for secondary fuel filter.
Remove bolts (11) fuel filter bracket (10).
Remove fuel filter bracket (10) from the valve mechanism cover.
If necessary, remove studs (9). from fuel filter bracket (10). Installation Procedure
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.
Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness and the convoluting.
Illustration 4 g03011038
If necessary, follow Step 1.a through Step 1.c in order to install the bracket for secondary fuel filter.
If necessary, install studs (9) to fuel filter bracket (10). Tighten studs (9) to a torque of 18 N m (159 lb in).
Position fuel filter bracket (10) onto the valve mechanism cover. Install bolts (11) to fuel filter bracket (10).
Tighten bolts (11) to a torque of 25 N m (221 lb in).
Illustration 5 g03011037
Ensure that fuel filter base (3) is clean and free from damage. If necessary, replace the complete fuel filter base and filter assembly.
Position fuel filter base (3) on the mounting bracket. Install nuts (6). Tighten the bolts to a torque of 25 N m (221 lb in).
If necessary, install a new fuel filter (7) to canister (8). Install cannister (8) to fuel filter base (3). Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.
Illustration 6 g03011036
Remove the plugs from the plastic