TOHATSU TLDI MD 115A SERIES, Service Manual

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TLDI 115A 2007 v
1.Service Information
1. Identification (Engine Serial Number) … 1-2
2. Securing of work safety ………… 1-2
1) Fire Prevention ……………………… 1-2
2) Ventilation …………………………… 1-2
3) Protection …………………………… 1-2
4) Genuine Parts ……………………… 1-2
5) Tools ………………………………… 1-3
6) Recommendations on service …… 1-3
7) Cautions in disassembling and assembling components … 1-4
3. Tools and Instruments …………… 1-5
1) Test Propeller ……………………… 1-5
2) Measuring instruments …………… 1-5
3) List of Special Tool ………………… 1-6
4. Pre-delivery Inspection …………… 1-10
1) Steering Handle …………………… 1-10
2) Gear Shift and Throttle …………… 1-10
3) Engine Oil …………………………… 1-10
4) Gear Oil ……………………………… 1-10
5) Check quantity of engine oil ……… 1-11
6) Fuel Line …………………………… 1-12
7) Installation of Outboard Motor (Rigging) … 1-12
8) Inspection of PTT Unit ……………… 1-12
9) Inspection of Start Switch and Stop switch … 1-13
10) Propeller Selection ………………… 1-14
11) Cooling Water Check Port ………… 1-14
12) Trim Tab …………………………… 1-15
5. Break-In Operation ………………… 1-15
6. Test Run ………………………………… 1-16
7. Checks After Test Run …………… 1-16
2.Service Data
1. Outboard Dimensions ……………… 2-2
1) Body dimensions ……………………… 2-2
2)Clamp Dimensions …………………… 2-3
2. Cooling Water System Diagram … 2-4
3. Specifications ………………………… 2-6
4.
Warning Indication List • • •
Display for abnormalities during operation
… 2-8
5. Torque Specifications …………… 2-10
6. Maintenance Data ………………… 2-12
7. Sealant And Lubricant …………… 2-18
3.Inspections and
Adjustments
1. Special Tool …………………………… 3-2
2. Inspection Schedule ……………… 3-3
3. Top Cowl ……………………………… 3-4
1) Adjustment of Cover Hook …………… 3-4
2) Oil Filter and Oil Tank ………………… 3-4
3) Air Bleeding …………………………… 3-5
4. Fuel System …………………………… 3-6
1) Inspection of Fuel Pipes and Joints … 3-6
2) Inspection of Fuel Filter ……………… 3-7
3) Inspection of Air Compressor Air Filter … 3-7
4) Inspection of Air Pressure …………… 3-7
5) Inspection of Fuel Pressure ………… 3-8
5. Cooling System ……………………… 3-9
1) Inspection of Cooling Water Passage … 3-9
2) Flushing with Water ………………… 3-10
3) Inspection of Compression Pressure … 3-13
6. Power Unit …………………………… 3-14
1) Inspection of Drive Belt ……………… 3-14
2) Adjustment of Drive Belt Tension …… 3-15
3) Inspection of Spark Plugs …………… 3-16
4) Inspection of Thermostat …………… 3-17
7. Operating System …………………… 3-18
1) Adjustment of Throttle Cable ………… 3-18
2) Adjustment of Shift Cable …………… 3-19
8. PTT System …………………………… 3-20
1) Inspection of PTT Unit Operation …… 3-20
2) Inspection of PTT Fluid Quantity …… 3-21
9. Lower Unit …………………………… 3-21
1) Inspection of Gear Oil Quantity ……… 3-22
2) Replacement of Gear Oil …………… 3-23
3) Inspection of Gear Case (for leakage) … 3-23
10. Others …………………………………… 3-24
1) Replacement of Anode ……………… 3-24
2) Inspection of Battery ………………… 3-25
3) Greasing ……………………………… 3-26
4.Fuel System (TLDI)
1. Special Tools
..................................... 4-2
2. Parts Layout
....................................... 4-3
Vapor Separator & Fuel Line .................. 4-3
FFP Ass'y................................................ 4-4
High Pressure Fuel Filter & Air Rail ........ 4-6
Air Compressor ....................................... 4-8
Oil Pump ................................................. 4-10
3. What is TLDI?
..................................... 4-12
Direct Fuel Injection System ................... 4-12
Inductive Ignition ..................................... 4-13
ECU ........................................................ 4-15
Fuel / Air Feed System ........................... 4-16
Oil System............................................... 4-17
Recirculation System .............................. 4-18
4. Removing Air Rail
............................. 4-19
1) Decompression of Fuel Line and Air Line .... 4-19
2) Removing Air Rail Ass'y ..................... 4-19
5. Assembling Air Rail
.......................... 4-21
1) Installing Injectors and Regulators...... 4-21
6. Removing Fuel System
................... 4-25
1) Removing Fuel Hose Ass'y................. 4-25
2) Attaching Fuel Hose Ass'y.................. 4-25
3) Draining Fuel from FFP Vapor Separator..... 4-26
4) Removing Vapor Separator ................ 4-26
5) Disassembly and Inspection of Vapor Separator... 4-27
6) Assembly of Vapor Separator............. 4-28
7) Assembly of Vapor Separator Ass'y ... 4-29
8) Removing FFP Ass'y .......................... 4-29
9) Disassembly and Inspection of FFP ... 4-29
10) Assembly of FFP Ass'y..................... 4-30
11) Attaching FFP Ass'y to Cylinder ....... 4-32
12) Inspection of Fuel Pump ................... 4-33
Air Piping of Air Compressor ............... 4-34
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