3V1-05098-0 Tohatsu STARTER CASE

Illustration 1 g02532497
Table 1
Specification for 261-0191 Cylinder Block Gp
Item Qty Parts Specification Description
1 1 227-1204 Gasket The bottom of spacer plate (2), the top of cylinder block, and both surfaces of gasket (1) must be free of fuel, oil, water, adhesives, assembly compounds or any other contaminants during assembly.
Thickness of the gasket is 0.20 0.02 mm (0.008 0.001 inch).
A 1 4N-1650 Dowel Apply green Loctite 609 to the dowel before installation.
Extension of dowel above the top surface of the cylinder block is 18.5 0.5 mm (0.73 0.02 inch).
2 1 6I-4421 Spacer Plate Maximum thickness of the spacer plate is 8.585 0.025 mm (0.3380 0.0010 inch).
B 1 1S-9540 Dowel Extension of dowel above the top surface of the cylinder block is 16.0 0.5 mm (0.63 0.02 inch).
C 1 6I-1055 Dowel Apply green Loctite 609 to the dowel before installation.
Extension of dowel above the top surface of the cylinder block is 20.0 0.5 mm (0.79 0.02 inch).
E 2 4N-0683 Dowel Extension of the dowel beyond the end of the cylinder block is 19.1 0.5 mm (0.75 0.02 inch).
3 - - Lubricate the bore of the O-ring seal lightly with the fluid that is being sealed.
G - - Installation depth of the plug 2.0 2.0 mm (0.08 0.08 inch)
Illustration 2 g02725181
Table 2
Item Qty Parts Specification Description
4 1 516-9693 Cylinder Block Liner Thoroughly lubricate the full inner diameter of the cylinder liner with clean engine oil.
5 - - Lubricate the bore of the O-ring seal lightly with the fluid that is being sealed.
H - - Dimension from the centerline of the crankshaft bearing bore to the top of a new cylinder block is 425.45 mm (16.750 inch).
J - - Bore in the cylinder block for the main bearings is 129.891 0.013 mm (5.1138 0.0005 inch).
K - - Width of the main bearing cap is 215.9 mm (8.50 inch).
Width of the cylinder block for the main bearing cap is 215.900 0.020 mm (8.5000 0.0008 inch).
L - - Dimension from the centerline of the crankshaft bearing bore to the bottom of cylinder block pan rails is 165.1 mm (6.50 inch).
6 14 3P-1323 Bearing Cap Bolts Use the following procedure to tighten the main bearing cap bolts:
1. Apply clean engine oil to the threads of the bolts.
2. Tighten the bolts that are in the tab end to 258 14 N m (190 10 lb ft).
3. Tighten the bolts that are opposite to the tab end to 258 14 N m (190 10 lb ft).
4. Again, tighten the bolts that are opposite to the tab end to an extra angle of 120 5 degrees.
4. Again, tighten the bolts that are in the tab end to an extra angle of 120 5 degrees.
Repeat the procedure for each bolt.
The total flatness of the top contact surface of the cylinder block must be within 0.10 mm (0.004 inch). The flatness must also be within 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) section of the surface.