0392000 JOHNSON EXHAUST FILLER BLOCK REPLACEMENT KIT

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01286511
Disconnect the thermocouples from the segments of the exhaust manifold that are being removed.
Remove the adapters, if necessary.
Loosen bolts (1) that mount exhaust manifold (2) to the cylinder head from the segment of the exhaust manifold that is on the end. Loosen bolts (3) that mount the segment of the exhaust manifold that is on the end to bellows (4). Loosen bolts (5) that mount bellows (4) that is on the end to the adjacent exhaust manifold.
Repeat Step 1 through Step 3 for the remaining segments of exhaust manifold (2). Move toward the turbocharger when you are loosening all of the remaining bolts.
Return to the segment of the exhaust manifold that is on the end. Attach a suitable lifting device to the segment of the exhaust manifold. The weight of each segment of exhaust manifold (2) is approximately 25 kg (55 lb).
Remove bolts (1) that mount exhaust manifold (2) to the cylinder head from the segment of the exhaust manifold that is on the end. Remove bolts (3) that mount the segment of the exhaust manifold that is on the end to bellows (4). Remove the segment of exhaust manifold (2). Remove the gasket. Remove bolts (5) that mount bellows (4) that is on the end to the adjacent exhaust manifold. Remove the bellows.
Repeat Step 5 and Step 6 for the remaining segments of exhaust manifold (2). Move toward the turbocharger when you are removing all of the remaining bolts. Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 5P-3931 Anti-Seize Compound -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Do not preassemble the exhaust system before installation of the engine. Damage to the bellows could result.
Apply Tooling (A) to the threads of the bolts of the exhaust manifold, the washers, the bolts of the bellows, the plugs and the adapters before installation.
Illustration 2 g01286511
Attach a suitable lifting device to a segment of the exhaust manifold. The weight of each segment of exhaust manifold (2) is approximately 25 kg (55 lb). Position the gasket and exhaust manifold (2) on the cylinder head. Install bolts (1) that mount the exhaust manifold to the cylinder head. Tighten the bolts finger tight. Note: Do not tighten these bolts to the torque specification at this time.
Repeat Step 2 for all segments of exhaust manifold (2).
Install bellows (4), bolts (5), and bolts (3) on the exhaust manifold. Tighten the bolts finger tight.
Tighten bolts (1) that mount exhaust manifold (2) to the cylinder head to a torque of 135 20 N m (100 15 lb ft).
Tighten bolts (3) and bolts (5) to a torque of 55 10 N m (41 7 lb ft).
If the adapters were removed, tighten the adapters to a torque of 200 25 N m (150 20 lb ft). End By:
Install the exhaust manifold shields. Refer to Disassembly and Assembly, "Exhaust Manifold Shield - Remove and Install".