F8039 Force PLAIN WASHER

Illustration 1 g01249215
Illustration 2 g01176473
Loosen bolts (2) and (5) in reverse numerical order. Refer to Illustration 2. This will help prevent distortion of the exhaust manifold.
Remove bolts (2) from exhaust manifold (3). Remove bolts (5) and spacers (4) from exhaust manifold (3).
Remove exhaust manifold gaskets (1) from the cylinder head.
If necessary, remove studs (6) from exhaust manifold (3).
Clean all of the components of the exhaust manifold assembly. Check all of the components for wear or for damage. Removal Procedure (Top Mounted Exhaust Manifold)
Start By:
Remove the turbocharger.
Illustration 3 g01249219
Illustration 4 g01176487
Loosen bolts (3) and (6) in reverse numerical order. Refer to Illustration 4. This will help prevent distortion of exhaust manifold (4).
Remove bolts (3) from exhaust manifold (6). Remove bolts (6) and spacers (5) from exhaust manifold (4).
Remove exhaust manifold gaskets (1) from the cylinder head.
If necessary, remove studs (2) from exhaust manifold (4).
Clean all of the components of the exhaust manifold assembly. Check all of the components for wear or for damage. Installation Procedure (Side Mounted Exhaust Manifold)
Table 1
Required Tools
Tool Part Number Part Description Qty
A M10 X - 1.5 by 100 mm
Guide Stud 4 Note: If a bolt for the exhaust manifold has become loose, or a bolt for the exhaust manifold must be loosened, all of the bolts for the exhaust manifold must be loosened. The bolts for the exhaust manifold must be tightened in the correct sequence and to the correct torque.
Illustration 5 g01176473
Illustration 6 g01249215
If necessary, install studs (6) to exhaust manifold (3). Tighten studs (6) to a torque of 18 N m (13 lb ft).
Install Tooling (A) in the cylinder head in Holes (X).
Position exhaust manifold gaskets (1) onto Tooling (A) in the cylinder head.
If the air port in the cylinder head is covered by the gasket, use the following procedure.
Remove exhaust manifold gasket (1) from the cylinder head.
Turn exhaust manifold gasket (1) through 180 degrees.
Reinstall exhaust manifold gasket (1) onto Tooling (A) in the cylinder head.
Position exhaust manifold (3) onto Tooling (A).
Install bolts (2) to exhaust manifold (3). Install spacers (4) and bolts (5) to exhaust manifold (3) in order to secure exhaust manifold (3) to the cylinder head.
Remove Tooling (A). Install remaining spacers (4) and bolts (5) and (2) to exhaust manifold (3).
Tighten bolts (2) and (5) to a torque of 44 N m (32 lb ft). Tighten bolts (2) and (5) in the sequence that is shown in Illustration 5. End By:
Install the turbocharger. Installation Procedure (Top Mounted Exhaust Manifold)
Table 2
Required Tools
Tool Part Number Part Description Qty
A M10 - 1.5 by 100 mm
Guide Stud 4 Note: If a bolt for the exhaust manifold has become loose, or a bolt for the exhaust manifold must be loosened, all of the bolts for the exhaust manifold must be loosened. The bolts for the exhaust manifold must be tightened in the correct sequence and to the correct torque.
Illustration 7 g01176487
Illustration 8 g01249219
If necessary, install studs (2) to exhaust manifold (4). Tighten studs (2) to a torque of 18 N m (13 lb ft).
Install Tooling (A) in the cylinder head in Holes (X).
Position exhaust manifold gaskets (1) onto Tooling (A) in the cylinder head.
If the air port in the cylinder head is covered by the gasket, use the following procedure.
Remove exhaust manifo