3Z0-77450-0 Tohatsu ASSEMBLY

Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-6357(1)
or
8T-3022(2) Connecting Rod Guide 1
B 235-0612 Lift Bracket 1
C 136-1452 Retaining Ring Pliers As 1
D 318-3117 Ring Expander Gp 1
E 443-4072 (3)
or
443-4073 (4) Cover 1
F - Board
51 mm by 152 mm by 1.8 m (2 inch by 6 inch by 6.0 ft) 2
G 1U-8692 Piston Pin Guide 1
(1) Use with V-engines
(2) Use with In-line engines
(3) For 6 and 8 cylinders
(4) For 12 and 16 cylindersStart By:
Remove the cylinder heads.
Remove the piston cooling jets.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Personal injury or death can occur from not following the proper procedure or the recommended tooling.To prevent the possibility of injury or death, follow the established procedure using the recommended tooling.
If more than one piston is to be removed, the crankshaft can turn due to the weight of the remaining pistons. Lock the position of the crankshaft in in order to prevent unexpected movement, personal injury, or component damage.
Remove carbon accumulation from the cylinders before the pistons are removed.
Remove the crankcase covers from the cylinder block.
Clean the carbon ridge from the top of the cylinder liner.
Remove the cylinder liner sleeve. Ensure that the cylinder liner sleeve is clean prior to installation.
Illustration 1 g03374720
Turn the crankshaft until nuts (2) that hold connecting rod cap (1) can be reached. Loosen nuts (2) that hold connecting rod cap (1). Do not remove nuts (2) at this time. Turn the crankshaft until the piston is at the TOP CENTER position.
Position Tooling (F) under connecting rod cap (1). Tooling (F) will span the engine to the openings of the inspection covers on the opposite side. The weight of connecting rod cap (1) is approximately 16 kg (35 lb).
Raise Tooling (F) to support connecting rod cap (1). Perform this procedure on the far side of the engine from connecting rod cap (1).
While you support connecting rod cap (1), carefully remove nuts (2). Tap connecting rod cap (1) with a suitable plastic hammer to loosen connecting rod cap (1) from connecting rod bolts (3). Discard nuts (2).
Carefully lower Tooling (F) and connecting rod cap (1). Remove connecting rod cap (1). Be sure to identify the lower half of the connecting rod bearing with each connecting rod cap.
Install Tooling (A) onto bolts (3) for the connecting rod. Tooling (A) will hold the upper half of the connecting rod bearing in position.
Illustration 2 g03374721
Personal injury or death can occur from not following the proper procedure or the recommended tooling.To prevent the possibility of injury or death, follow the established procedure using the recommended tooling.
Attach Tooling (B) to the top of piston (4). If necessary, use a suitable tap to clean the holes.
Attach a suitable lifting device to Tooling (B). The combined weight of piston (4) and connecting rod (7) is approximately 125 kg (275 lb).Note: Observe the removal of piston (4) and connecting rod (7) at the top and at the bottom. Be sure that there are no points of interference.
Remove piston (4) and connecting rod (7) from the engine.
Position Tooling (E) on the connecting rod bearing journal.
Use the suitable lifting device and Tooling (B) to position piston (4) and connecting rod (7) in a VERTICAL position onto a suitable surface. Use two people to separate piston (4) and connecting rod (7). Use Tooling (C) to remove retaining rings (3). Use Tooling (G) to remove piston pin (6). Hold connecting rod (7) in a VERTICAL position to prevent the connecting rod from falling. Use the suitable lifting device and Tooling (B) to remove piston (4) from connecting rod (7). The weight of connecting rod (7) is approximately 54 kg (120 lb). The weight of piston (4) is approximately 36 kg (80 lb).
Position piston (4) onto a suitable surface. Remove the suitable lifting device and Tooling (B).