878380 Mercury GATE, Reverse - With Bumper

Illustration 1 g02478716
Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.
Remove bolts (2) and bolt (9) from tube assembly (3).
Remove tube assembly (3) from the cylinder head and the exhaust cooler.
Remove gasket (1) (not shown) and gasket (10) (not shown) from tube assembly (3).
Prior to and during removal of bolts (6) and bolts (11) apply releasing fluid to the bolts. Remove bolts (6) and bolts (11) from tube assembly (8).
Remove tube assembly (8) from the exhaust cooler and the exhaust manifold.
Remove gasket (7) (not shown) and gasket (12) (not shown) from tube assembly (8).
Remove bolt (5) and bolt (13) from dipstick tube assembly (4).
Loosen nut (14) on dipstick tube assembly (4). Remove the dipstick tube assembly.
Remove O-ring seal (15) (not shown) and seal (16) (not shown) from the dipstick tube assembly.
Illustration 2 g02477641
Tighten sequence of exhaust manifold
Illustration 3 g02478717
Loosen bolts (15) in reverse numerical order. Refer to Illustration 2. Note: Loosen the bolts in reverse numerical order will help prevent distortion of the exhaust manifold.
Remove bolts (15) and spacers (16) from exhaust manifold (17). Note position of the different length spacer. Note: Support the manifold as the bolts are removed.
Remove exhaust manifold (17).
Remove exhaust manifold gasket (18) (not shown). Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 366-1820 Manifold Alignment Pins 2
B 377-2038 Manifold Alignment Pins 1
C - Loctite 575 1
Ensure that the exhaust manifold is clean and free from damage. If necessary, replace the exhaust manifold. Clean the gasket surface of the cylinder head.
Illustration 4 g02477697
Tighten sequence of exhaust manifold and Tooling position
Illustration 5 g02478717
Position a new exhaust manifold gasket (18) (not shown) onto the cylinder head. Install Tooling (A) in Positions (X) and Tooling (B) in Positions (Y). Refer to Illustration 4. Note: Ensure that the exhaust manifold gasket is correctly oriented.
Align exhaust manifold (17) with Tooling (A) and Tooling (B). Install the exhaust manifold to the cylinder head.
If bolts (15) have been previously used, thoroughly clean the bolts. Tooling (C) should be applied to the first two threads of the bolts. Note: Do not apply Tooling (C) to new bolts.
Install bolts (15) and spacers (16) hand tight. Ensure that the different length spacer is installed into the correct position.
Remove Tooling (A) and Tooling (B). Install remaining bolts (15) and spacers (16) hand tight.
Tighten bolts (15) to a torque of 44 N m (32 lb ft). Tighten the bolts in the sequence that is shown in Illustration 4.
Illustration 6 g02478716
Ensure that all tube assemblies are free from restriction and damage.
Position a new gasket (7) (not shown) and a gasket (12) (not shown) onto tube assembly (8).
Install tube assembly (8) onto the exhaust cooler and the exhaust manifold.
Install bolts (6) and bolts (11) to tube assembly (8). Tighten the bolts to a torque of 22 N m (195 lb in).
Position a new gasket (1) (not shown) a new gasket (10) (not shown) onto tube assembly (3).
Install tube assembly (3) onto the cylinder head and the exhaust cooler.
Install bolts (2) and bolt (9) to tube assembly (3).
Tighten bolt (9) to a torque of 18 N m (159 lb in). Tighten bolts (2) to a torque of 22 N m (195 lb in).
Install a new O-ring seal (15) (not shown) and a new seal (16) (not shown) to the dipstick tube assembly. Loosely install nut (14) for dipstick tube assembly (4).
Install bolt (5) and bolt (13) to dipstick tube assembly (4).
Tighten nut (14) to a torque of 18 N m (159 lb in). Tighten bolts (5) and bolt (13) to a torque of 22 N m (195 lb in).
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure. End By:
Install turbocharger for top mounted turbocharged engine. Refer to Disassembly and Assembly, "Turbocharger (Top Mounted Turbocharger) - Install" for the correct procedure.
Install turbocharger for side mounted turbocharged engine. Refer to Disassembly and Assembly, "Turbocharger (Side Mounted Turbocharger) - Remove" for the correct procedure.