TOHATSU TLDI MD 115A SERIES Service Manual page 7

Structure of Air Compressor ............... 4-35
7. Removing Air Compressor ............. 4-36
1) Removing Drive Belt ........................... 4-36
2) Removing Air Compressor .................. 4-36
3) Inspection of Drive Belt ....................... 4-37
4) Removing Driven Pulley ..................... 4-38
5) Disassembly of Compressor Housing ...... 4-39
6) Inspection of Reed Valve .................... 4-39
7) Inspection of Cylinder and Piston ....... 4-39
8) Assembly of Compressor Housing ..... 4-40
9) Installation of Crank Shaft ................... 4-41
10) Installation of Piston .......................... 4-42
11) Installation of Compressor Housing Ass'y ......... 4-43
12) Measurement of Fuel Pressure and Air Pressure .... 4-44
13) Inspection of Oil Filter ....................... 4-46
14) Inspection of Oil Tank ....................... 4-46
15) Air Bleeding ...................................... 4-47
Arrangement of Oil Feed Lines ........... 4-48
Arrangement of Recirculation hoses ...... 4-49
5.Power Unit
1. Special tools .............................. 5-2
2. Parts Layout .............................. 5-3
Engine .......................................... 5-3
Magneto.......................................... 5-4
Electric Parts.................................... 5-6
Electric Parts (Starter Motor) ............... 5-8
Air Chamber .................................... 5-9
Throttle .......................................... 5-10
Cylinder Crank Case ........................ 5-12
Piston & Crank Shaft ........................ 5-14
3. Inspection Items ........................ 5-15
1) Removing Power Unit .................. 5-15
2) Removing Flywheel ..................... 5-19
3) Removing Stator Coil .................. 5-20
4) Removing Cord Ass'y .................. 5-21
5) Removing Throttle Link ............... 5-24
6) Removing Air Chamber ............... 5-25
7) Inspection of Throttle Body............ 5-26
Exploded Diagram of Short Block ... 5-28
Exploded Diagram of Piston-Crank Shaft Assembly ... 5-29
8) Removing Thermostat .................. 5-30
9) Removing Cylinder Head / Head Cover ... 5-31
10) Inspection of Cylinder Head ......... 5-32
11) Removing Exhaust Cover ............ 5-33
12) Inspection of Exhaust Cover ......... 5-33
13) Removing Crank Case ............... 5-34
14) Removing Pistons ..................... 5-35
15) Disassembly of Crank Shaft ......... 5-36
16) Inspection of Crank Shaft ............ 5-36
17) Inspection of Engine Parts ............ 5-38
18) Inspection of Pistons .................. 5-39
19) Assembling Crank Shaft ............... 5-42
20) Installing Pistons ........................ 5-43
21) Assembling Power Unit Parts ...... 5-44
22) Assembling Crank Case Halves ... 5-46
23) Assembling Exhaust Cover Parts ... 5-47
24) Assembling Cylinder Head Parts ... 5-49
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25) Assembling Coil Bracket Parts ...... 5-50
26) Assembling Crank Case Head Parts ... 5-50
27) Installing Air Chamber .................. 5-51
28) Attaching Coil Bracket .................. 5-53
29) Attaching Recirculation Hoses ...... 5-54
30) Installing Alternator ..................... 5-55
31) Installing Flywheel ..................... 5-55
32) Installing Power Unit .................. 5-56
6.Lower Unit
1. Special tools .............................. 6-2
2. Parts Layout .............................. 6-4
Gear Case (Drive Shaft) ..................... 6-4
Gear Case (Propeller Shaft) ............... 6-6
3. Inspection Items ........................ 6-8
1) Draining Gear Oil ........................ 6-8
2) Removing Propeller ..................... 6-8
3) Removing Lower Unit .................. 6-9
4) Removing Water Pump ............... 6-10
5) Inspection of Water Pump ............ 6-11
6) Disassembly of Water Pump Case (Lower) ... 6-12
7) Assembly of Water Pump Case (Lower) ... 6-12
8) Removing Propeller Shaft Housing Ass'y ... 6-13
9) Disassembly of Propeller Shaft Housing Ass'y ... 6-14
10) Inspection of Propeller Shaft Housing... 6-15
11) Assembly of Propeller Shaft Housing ... 6-16
12) Disassembly of Propeller Shaft Ass'y ... 6-19
13) Inspection of Propeller Shaft Ass'y ... 6-20
14) Assembly of Propeller Shaft Ass'y ... 6-20
15) Disassembly of Cam Rod ............ 6-21
16) Inspection of Clutch Cam ............ 6-22
17) Assembly of Clutch Cam Parts ...... 6-22
18) Removing Forward (A) Gear Ass'y ... 6-23
19) Disassembly of Forward Gear (A) Gear ... 6-24
20) Inspection of Forward (A) Gear ...... 6-24
21) Assembly of Forward (A) Gear Parts ... 6-25
22) Removing Drive Shaft Ass'y ......... 6-26
23) Disassembly of Drive Shaft Ass'y ... 6-27
24) Inspection of Drive Shaft............... 6-28
25) Assembly of Drive Shaft Parts ...... 6-28
26) Disassembly of Gear Case............ 6-30
27) Inspection of Forward (A) Gear and
Pinion (B) Gear........................... 6-31
28) Inspection of Gear Case ............... 6-31
29) Assembly of Gear Case Parts ...... 6-32
30) Assembly of Lower Unit Parts ...... 6-34
31) Attaching Clutch Cam Ass'y ......... 6-37
32) Installation of Lower Unit ............ 6-38
33) Measurement of Pinion (B) Gear Height
and Shim Selection ..................... 6-40
34) Measurement of Back Lash between Forward (A) and
Pinion (B) Gears and Shim Selection ......... 6-42
35) Measurement of Back Lash between Pinion (B) and
Reverse (C) Gears and Shim Selection ...... 6-45
36) Measurement of Propeller Shaft Play and
Selection of Washer Thickness ......... 6-48
7.Cowl, Bracket and PTT
TLDI 115A 2007