Table Of Contents - TOHATSU TLDI 40 Service Manual

Table of Contents

Specifications2
Specifications Table4
Outline Dimensions5
External Dimensions6
Background On Tldi7
Two-Stroke Low-Pressure Direct Injection (Tldi)7
Air-Assisted Low-Pressure Direct Injection7
Ecu Control8
Long-Duration Cdi (L-Cdi)9
Throttle-Position Sensor (Tps)9
Crank-Position Sensor (Cps)9
Water-Temperature Sensor (Wts)9
Fuel Supply System10
Air Supply System Diagram11
Oil Supply System Diagram12
Servicing Information14
Table Of Contents14
General Precautions For Servicing16
Specifications And Standards Used In Servicing17
Lists Of Points For Applying Sealant, Adhesive And Lubrication23
Torque Table29
Special Tools30
Using The Special Tool32
Pressure Gage Assembly32
Crankshaft Holder (3T5-72815-0)33
Drive Pulley Puller Assembly34
Drive Pulley Press (3T5-72868-0)35
Piston Slider (3T5-72871-0)35
Inserting Drive Pulley35
Installing Air Compressor Piston35
O-Ring Setting Tool (O24) (3T5-72863-0)36
Crimping Pliers (3T5-72864-0)36
Inspection And Maintenance38
Periodic Inspections39
Inspecting Engine Oil Systems40
Inspecting Compression System41
Cleaning Fuel Tank Filter41
Cleaning Fuel Tank41
Inspecting Gear Case Area42
Replacing Propeller42
Replacing Gear Oil42
Washing Procedure43
Inspecting Cooling System43
Thermostat Test43
Replacing Pump Impeller43
Overview Of Cooling System44
Tubing44
Inspecting Power Trim And Tilt System45
Inspecting Air Rail Pressure45
Disassembling, Inspecting And Reassembling Power Unit46
Power Unit47
Removing Power Unit48
Reassembling Power Unit50
Peripheral Parts51
Electrical System51
Removing Cps, Flywheel And Alternator51
Removing Ecu52
Removing Harness Assembly53
Removing Ignition Coil And Rectifier Regulator54
Air Supply System - Prior To Removing Peripheral Components55
Removing Air Compressor56
Inspecting Drive Belt56
Air Compressor Configuration57
Inspecting Air Compressor58
Assembling Piston59
Assembling Compressor59
Disassembling Air Rail61
Air Rail Assembly Configuration62
Inspecting Air Rail63
Assembling Air Rail64
Fuel System65
Disassembling Fuel Hose Assembly65
Assembling Fuel And Air Assembly65
Disassembling Vapor Separator66
Vapor Separator Configuration67
Inspecting Vapor Separator67
Assembling Vapor Separator68
Assembling Vapor Separator Assembly68
Disassembling Ffp Assembly68
Ffp Configuration69
Inspecting Ffp70
Assembling Ffp71
Installing Ffp Assembly On Cylinder73
Oil Pump74
Disassembling Oil Pump And Oil Tank74
Assembling Oil Pump And Oil Tank75
Throttle Mechanism76
Disassembling Advancer Arm76
Assembling Advancer Arm77
Disassembling Tps77
Assembling Tps78
Disassembling Air Box And Throttle Body78
Assembling Air Box79
Assembling Air Box And Throttle Body79
Disassembling Engine Block80
Cylinder And Crankcase Assembly Diagram80
Piston And Crankshaft Diagram81
Removing Thermostat82
Disassembling Cylinder Head And Head Cover82
Inspecting Engine Anode82
Inspecting Cylinder Head83
Disassembling Exhaust Cover84
Inspecting Exhaust Cover84
Disassembling Crankcase84
Disassembling Drive Pulley85
Removing Piston86
Inspecting Engine Components87
Inspecting Cylinders87
Inspecting Piston87
Inspecting Piston Rings88
Inspecting Crankshaft88
Assembling Piston Procedure89
Assembling Short Block90
Assembling Crankshaft90
Assembling Crankcase91
Assembling Cylinder Head91
Assembling Exhaust Cover92
Installing Recirculator Hose92
Installing And Inspecting Electrical Components94
Wire Routing95
Magneto View97
Electric Parts View98
Switch Box (F Type) View99
Wiring Diagram - Epto101
Wiring Diagram - Efto103
Wiring Diagram - Efo105
Epto Parts List107
Efto Parts List108
Efo Parts List109
Solenoid Bracket Assembly110
Flywheel Magneto Inspection115
Rectifier Regulator Inspection115
Rectifier Checkpoint Table115
Starter Motor Inspection116
Armature Inspection116
Disassembly, Inspection And Reassembly Lower Unit118
Gear Case (Drive Shaft) Diagram119
Configuration119
Gear Case (Propeller Shaft) Diagram120
Lower Unit Disassembly121
Disassembling Gear Case121
Removing Propeller121
Removing Gear Case121
Disassembling Water Pump Case122
Disassembling Propeller Shaft And Clutch122
Removing Bevel Gear And Drive Shaft123
Lower Unit Inspection124
Inspecting Bevel Gear Backlash125
Backlash Reading And Corresponding Adjusting Shim Sizes125
Lower Unit Reassembly126
Assembling Gear Case126
Installing Bevel Gear On Drive Shaft126
Assembling Propeller Shaft And Clutch126
Assembling Clutch Cam, Cam Rod And Clutch Cam Rod Bushing127
Assembling Water Pump128
Adding Gear Oil129
Assembling Gear Case Assembly129
Power Trim And Tilt130
Power Trim And Tilt Configuration131
Power Trim And Tilt - Names Of Parts132
Power Trim And Tilt - Troubleshooting133
Checking Procedure135
Are There Any Internal Malfunctions In The Pt & T?139
Disassembly And Assembly (Pt & T)141
Precautions For Disassembling And Assembling Power Trim And Tilt (Pt&T) System141
Tiller Handle Type142
Installing Gearshift Lever Assembly143
Installing Switchbox Assembly144
Installing Handle To Engine145
Troubleshooting146
Troubleshooting Tables147
Tldi Self-Diagnosing Functions159
Glossary Of Self-Diagnosis Terminology159
Self-Diagnosing Function Procedures160
Using The Self-Diagnosing Function161
Warning Indicator Definition Table .... While Operating Engine163
Engine Operating Hours Table (Self-Diagnosing Mode 2)164
Fault Indication Table (Self-Diagnosing Mode 3)165
Resetting Tps Initial Values167
Reset Procedure Chart167
Test Run And Inspection After Servicing168
Test Run Tank And Test Propeller169
Test Run Tank Requirements And Precautions For Use169
Test Propeller169
Items To Check Prior To Test Run170
Items To Check During The Test Run170
Additional Tightening After Test Run170
Breaking In Engine170
Installation On Boat And Test Run172
Precautions For Using This Engine173
Remote Control System - Installing Cable (Engine Side) For Ep Series173
Gauges And Battery175
Installing The Various Gauges175
Installing Battery176
Wiring Diagram For Remote Control Unit And Gauges176
Operating The Engine177
Starting Procedure177
Force-Feeding Fuel178
Force-Feeding Engine Oil178
Efo And Efto Series179
Epto Series180
Warning Process181
Oil Level Indicator181
Cooling Water Indicator182
Battery Level Warning182
Engine Trouble Warning183