9402E3-1200 Tohatsu WASHER

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Guide Bolt
(M16 by 115mm) 2
B - Straight Edge 1
C 8T-3052 Degree Wheel 1
D 1U-6396 O-Ring Assembly Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Thoroughly clean the mating surfaces of the cylinder head and the cylinder block. Do not damage the mating surfaces of the cylinder head or the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.
Inspect the mating surface of the cylinder head for distortion. Refer to Specifications, "Cylinder Head" for more information.
Illustration 1 g01324063
Typical example
Inspect dowels (9) for damage. If necessary, replace the dowels in the cylinder block.
Install Tooling (A) to the cylinder block. Refer to Illustration 1.
Align cylinder head gasket (10) with Tooling (A) and with dowels (9). Install the cylinder head gasket onto the cylinder block.
Illustration 2 g01323631
Typical example
Use a suitable lifting device (8) to lift the cylinder head. The weight of the cylinder head is approximately 56 kg (124 lb). Note: It is advisable to use a spreader bar during the lifting operation in order to distribute the weight of the cylinder head.
Use Tooling (A) to align cylinder head (7) with the cylinder block. Install the cylinder head to the cylinder block. Note: Ensure that the cylinder head is correctly positioned onto dowels (9).
Illustration 3 g01324064
Clean bolts (6). Follow Steps 8.a and 8.b for the procedure to inspect the bolts.
Check the length of the bolts.
Use Tooling (B) in order to check the threads of the bolts. Refer to Illustration 3. Replace any bolts that show visual reduction in the diameter of the thread over length (Y).
Lubricate the threads and the shoulder of bolts (6) with clean engine oil.
Remove Tooling (A).
Illustration 4 g01323622
Install bolts (6) to cylinder head (7). Note: There are two different lengths of bolts (6) for cylinder head (7). Install longer bolts in position (X) in the cylinder head.
Illustration 5 g01352300
Sequence for tightening the bolts for cylinder head
Tighten bolts (6) to a torque of 50 N m (37 lb ft) in the sequence that is shown in Illustration 5.
Tighten bolts (6) to a torque of 100 N m (74 lb ft) in the sequence that is shown in Illustration 5.
Illustration 6 g01352369
(A) Short bolts
(B) Long bolts
Use Tooling (C) to turn bolts (6) through an additional angle in the sequence that is shown in Illustration 5. Turn the long bolts through 270 degrees.Turn the short bolts through 225 degrees.
Illustration 7 g01344073
Install new O-ring seals (4) and (5) to bypass tube (3). Use Tooling (D) in order to lubricate O-ring seal (5). Install the bypass tube to the cylinder head. Install bolts (2). Ensure that any brackets that are secured by the bolts are installed in the correct position. Tighten the bolts to a torque of 22 N m (16 lb ft).
Connect the harness assembly to sensor (1).
If the alternator bracket is mounted on the cylinder head, Install the alternator. Refer to Disassembly and Assembly, " Alternator - Remove".
Install the injectors. Refer to Disassembly and Assembly, "Injector - Install".
Install the glow plugs. Refer to Disassembly and Assembly, "Glow Plugs - Remove and Install".
If the fuel priming pump and the fuel filter base are mounted on the cylinder head, install the fuel priming pump and the fuel filter base. Refer to Disassembly and Assembly, "Fuel Priming Pump and Fuel Filter Base - Remove and Install".
Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install".
If necessary, install the air hose to the inlet connection.
If necessary, install the water temperature regulator housing to the cylinder head. Refer to Disassembly and Assembly, "Water Temperature Regulator Housing - Remove and Install".
Connect the upper radiator hose to the water temperature regulator housing .
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct filling procedure.
If necessary, fill the engine oil pan to the correct level. Refer to Operation and Maintenance Manual, "Engine Oil Level - Check".