822401 1 Mercury CAP

Table 1
Required Tools
Tool Part Number Part Description Qty
B(1) 366-1820 Manifold Alignment Pins 2
C(2) 366-1819 Manifold Alignment Pins 2
(1) Tooling (B) is used to hold the gasket in position and align the exhaust manifold.
(2) Tooling (C) is used to align the exhaust manifold.
Illustration 1 g02565517
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged. Refer to Specifications, "Exhaust Manifold" for the correct exhaust manifold tolerances. Refer to Specifications, "Turbocharger" for the correct turbocharger tolerances.
Clean all gasket surface's prior to assembly.
If necessary, install studs (43). Tighten the studs to a torque of 18 N m (159 lb in)
Position new gasket (42) onto exhaust manifold (38).
Install turbocharger (5) to the exhaust manifold.
Install nuts (41). Tighten the nuts to a torque of 44 N m (33 lb ft)
If necessary, install back pressure valve adapter (40) to the turbocharger. Refer to Disassembly and Assembly, "Exhaust Back Pressure Valve - Remove and Install" for the correct procedure.
If tube assembly (46) has been removed, position new gasket (44) and new gasket (47) onto tube assembly (46). Position tube assembly (46) onto exhaust manifold (38). Install new bolts (45) to the tube assembly hand tight and ensure that tube assembly can move freely.
Illustration 2 g03423094
Illustration 3 g02565598
Position a new exhaust manifold gasket (35) (not shown) onto the cylinder head. Install Tooling (B) in Position (W). Install Tooling (C) in Position (V). Refer to Illustration 2.Note: Ensure that the exhaust manifold gasket is correctly oriented.
Position a new exhaust manifold gasket (36) (not shown) onto the cylinder head. Install Tooling (B) in Position (X). Install Tooling (C) in Position (Y) Refer to Illustration 2.Note: Ensure that the exhaust manifold gasket is correctly oriented.
Align exhaust manifold (38) with Tooling (B) and Tooling (C). Install the exhaust manifold to the cylinder head.
Install new bolts (37) and spacers (34) in the eight available positions on exhaust manifold (38).
Tighten bolts (37) one to four to a torque of 44 N m (32 lb ft). Tighten the bolts in the sequence that is shown in Illustration 2.
Remove Tooling (B) and Tooling (C) from the cylinder head. Install remaining bolts (37) and spacers (34) to exhaust manifold (38).
Tighten remaining bolts (37) to a torque of 44 N m (32 lb ft). Tighten the bolts in the sequence that is shown in Illustration 2.
Install bolts (21) to tube assembly (22).
Tighten bolts (21) and bolts (45) to a torque of 22 N m (195 lb in).
Illustration 4 g02567636
Position a new gasket (24) (not shown) onto the induction mixer.Note: Ensure that the gasket is correctly installed onto the locating dowels in the induction mixer.
Position a new gasket (30) (not shown) onto tube assembly (25).
Position tube assembly (25) between the bracket and the induction mixer. Install bolts (23) finger tight.
Position tube assembly (25) onto the exhaust cooler. Install bolts (29) finger tight.
Tighten bolts (29) to a torque of 18 N m (159 lb in).Tighten bolts (23) to a torque of 22 N m (195 lb in).Tighten bolts (33) to a torque of 44 N m (32 lb ft).Note: Ensure that tube assembly (25) is not stressed as the bolts are tightened.
Position a new gasket (27) (not shown) and a new gasket (31) (not shown) onto tube assembly (28).
Position tube assembly (28) onto the exhaust cooler and the cylinder head. Install bolts (26) and bolts (32). Tighten the bolts hand tight.
Tighten bolts (26) to a torque of 22 N m (195 lb in).Tighten bolts (32) to a torque of 18 N m (159 lb in).Note: Ensure that tube assembly (28) is not stressed as the bolts are tightened.
Illustration 5 g02518517
Illustration 6 g02568217
Install bolts (16) and install bolt (20) to the clips for tube assembly (17). Tighten bolts (16) to a torque of 18 N m (159 lb in).Tighten bolt (20) to a torque of 22 N m (195 lb in).Note: Ensure that tube assembly (17) is not stressed as the bolts are tightened.
Connect hose assembly (19) to tube assembly (17). Slide hose clip (18) into the correct position.
Install new gasket (13) to tube assembly (15).
Position tube assembly (15) onto the turbocharger.
Install bolts (14). Tighten the bolts to a torque of 11 N m (97 lb in).
Lubricate the turbocharger bearings with clean engine oil through the oil inlet port in Position (A). Rotate the wheel of the compressor several times in order to lubricate the bearings.
Position a new sealing washer (11) onto banjo bolt (10). Install the banjo bolt to tube assembly (12).
Position the remaining new sealing washer (11) onto the banjo bolt. Install the banjo bolt finger tight.
Tighten banjo bolt (10) to a torque of 15 N m (133 lb in)