0435299 JOHNSON JET FLUSHING DEVICE

At operating temperature, the exhaust manifolds are hot. Any contact with the hot exhaust manifolds can cause severe burns. Prior to working on the exhaust manifolds, allow engine to cool.
1. Remove left hand door assemblies (1) and (3) from engine enclosure tube assembly (2). Remove left hand door assemblies (4) and (6) from engine enclosure tube assembly (5). Remove left hand door assembly (7) from the engine enclosure. The engine enclosure tube assemblies must be moved slightly to remove the exhaust manifolds. Move the engine enclosure tube assemblies from the frame assembly, enough to remove the exhaust manifold off the studs. Do one side of the machine at a time.2. Remove two bolts (8) and the hard washers from engine enclosure tube assembly (5). Pull engine enclosure tube assembly (5) off rear frame assembly (9). 3. Remove two bolts (10) and the hard washers from engine enclosure tube assembly (2). Pull engine enclosure tube assembly (2) off rear frame assembly (9). 4. Loosen clamp (12) from exhaust manifold (11). Remove twelve locknuts (13), the washers and twelve spacers (6). While pulling the engine enclosure tube assemblies, remove exhaust manifold (11) from the engine block. 5. Remove six exhaust manifold gaskets (15) from exhaust manifold (11).6. Separate the three manifold sections of exhaust manifold (11). The following steps are for the installation of the exhaust manifold.7. Make sure all components of the exhaust manifold are clean of dirt and foreign material prior to installation. Remove all gasket material from the mating surfaces of the exhaust manifold.8. Check all components for wear or damage and replace if necessary. 9. Apply 4C-5599 Anti-Seize Compound to the outside diameter of the male ends of the manifold sections. Apply oil to the inside diameters of the female ends of the manifold sections.11. Apply 4C-5599 Anti-Seize Compound to twelve studs (16). Install six exhaust manifold gaskets (15) and assembled exhaust manifold (11) on studs (16). 12. Using the torque sequence chart, insert Tooling (A), (not show) on studs 7, 9, and 11 for the left side exhaust manifold and studs 4, 7, and 9 for the right side exhaust manifolds.13. Install 12 spacers (14), 12 new locknuts (13), and the washers that hold exhaust manifold (11) to the engine block. Tighten 12 locknuts (13) in the sequence shown on the chart, to a pre-torque of 20 3 N m (15 2 lb ft). Remove each manifold guide [Tooling (A)] as needed to tighten each locknut (11).14. After pre-torque has been obtained, tighten twelve locknuts (13) in the sequence shown on the chart, to a torque of 38 5 N m (28 4 lb ft). 15. Tighten clamp (12) to exhaust manifold (11). 16. Put engine enclosure tube assembly (2) in position on rear frame assembly (9). Install two bolts (10) and the hard washers to engine enclosure tube assembly (2). 17. Put engine enclosure tube assembly (5) in position on rear frame assembly (9). Install two bolts (8) and the hard washers to engine enclosure tube assembly (5). 18. Install left hand door assemblies (1) and (3) to engine enclosure tube assembly (2). Install left hand door assemblies (4) and (6) to engine enclosure tube assembly (5). Install left hand door assembly (7) to the engine enclosure.19. If necessary, repeat this procedure on the remaining exhaust manifold.