3R4-00001-3 Tohatsu PISTON

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more information. If the turbocharger is worn, the complete turbocharger must be replaced.
Test the turbocharger actuator for correct operation. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more information. If the actuator is damaged or the actuator does not operate within the specified limits, the complete turbocharger must be replaced.
Illustration 1 g03791638
Illustration 2 g03791640
If necessary, follow Step 3.a through Step 3.r in order to install boost pressure chamber cover (40).
Position new gasket (38) (not shown) onto boost pressure chamber cover (40).
Position boost pressure chamber cover (40) onto engine oil cooler (37). Install bolts (26). Tighten the bolts to a torque of 10 N m (89 lb in)
Install a new sealing washer (35) (not shown) onto banjo bolt (36). Install the banjo bolt to hose assembly (29) and install remaining new sealing washers (35) (not shown).
Position hose assembly (29) onto boost pressure chamber cover (40). Tighten banjo bolt (36) finger tight.
Connect hose assembly (29) to wastegate solenoid (31).
Install hose assembly (29) to the correct clips (28). Surely tighten hose clamp (30).
Connect hose assembly (5) to wastegate solenoid (31).
Install hose assembly (5) to the correct clips (28). Surely tighten hose clamp (32).
Install a new sealing washer (34) (not shown) onto banjo bolt (33). Install the banjo bolt to hose assembly (9) and install remaining new sealing washers (34) (not shown).
Position hose assembly (9) onto boost pressure chamber cover (40). Tighten banjo bolt (33) finger tight.
Install clip (41) to hose assembly (29) and hose assembly (9).
Tighten banjo bolt (33) and banjo bolt (36) to a torque of 12 N m (106 lb in). Ensure that the hose assemblies are not strained or come into contact with other components as the banjo bolts are tightened.
Install a new O-ring seal (25) (not shown) to tube assembly (26).
Install tube assembly (26) to oil cooler (37). Ensure that the tube assembly is correctly located into the engine oil cooler.
Install bolts (24) and bolt (27) hand tight.
Tighten bolts (24) to a torque of 25 N m (221 lb in).
Tighten bolts (27) to a torque of 22 N m (195 lb in).
Install the mounting bracket and alternator (23). Refer to Disassembly and Assembly, "Alternator - Remove and Install" for the correct procedure.
Illustration 3 g03791639
Clean the gasket surfaces of exhaust manifold (19) and turbocharger (10).
If necessary, install studs (18) to exhaust manifold (19) and turbocharger (10). Tighten the studs to a torque of 15 N m (133 lb in).
Position a new gasket (20) (not shown) onto turbocharger (10).
Position turbocharger (10) onto exhaust manifold (19). Note: Do not use the actuator rod to lift the turbocharger.
Install new nuts (17). Tighten the nuts to a torque of 28 N m (248 lb in).
If necessary, follow Step 9.a through Step 9.b in order to install adapter (21) to the cylinder block.
Install a new sealing washer (22) (not shown) to adapter (21).
Install adapter (21) to the cylinder block. Tighten the adapter to a torque of 28 N m (248 lb in).
Illustration 4 g03791637
Install new O-ring seals (12) (not shown) to tube assembly (11).
Install tube assembly (11) to the cylinder block. Ensure that the tube assembly is not damaged as the tube assembly is installed from the cylinder block. Ensure that correct orientation of the tube assembly.
Position a new gasket (13) (not shown) between tube assembly (11) and turbocharger (10).
Install Allen head bolts (14) to tube assembly (11). Tighten the Allen head bolts to a torque of 10 N m (89 lb in).
Lubricate the bearings of the turbocharger with clean engine oil through the oil inlet port. Rotate the shaft of the turbocharger in order to distribute the lubricant.
Position tube assembly (3) onto turbocharger (10) and the cylinder block. Tighten nut (15) finger tight.
Install a new sealing washer (1) (not shown) to banjo bolt (2). Install the banjo bolt to tube assembly (3) install remaining new sealing washer between the tube assembly and turbocharger (10). Hand tighten the banjo bolt.
Tighten banjo bolt (2) to torque of 22 N m (195 lb in). Ensure that the tube assembly is not strained as the banjo bolt is tightened.
Tighten tube nut (15) to torque of 22 N m (195 lb in).
Connect hose assembly (9) to wastegate actuator (16) (not shown). Securely tighten hose clamp (8) (not shown).
Connect hose assembly (5) to turbocharger (10). Securely tighten hose clamp (6).
Connect hose assemblies to turbocharger inlet (7) and from turbocharger outlet (4). Tighten the hose clamp securely.
Fill the coolant from the coolant system. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.
Install the flexible exhaust pipe to the turbocharger. Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure.