VPA 7748089 English 09-2007
39
Engine — 5.0 & 5.7 Litre
Each area/section of gasket mounting surface (see example in pic-
ture) should be flat and smooth to a tolerance of 0.1mm.
If the surface can not be cleaned or sanded to this tolerance, the part
must be machined flat at the gasket mounting surface.
If machined, the following applies;
• The maximum material that can be removed is 0.25mm
(0.0098 in.)
• Machine flatness over the gasket surface is 0.075mm
(0.0029 in.) maximum overall, with not more than 0.02mm
(0.000787 in.) allowable over any 25mm (0.98 in.) span.
• Surface finish should not exceed 0.0032mm (0.0001259 in.)
Roughness Average
If the surface can not be machined to these specifications the part
must be replaced.
7.
Place gasket over mounting surface on manifold.
NOTICE!
Be careful not to scratch or cut the black coating on
the riser gasket.
NOTICE!
Do not use any sealant on the riser gasket.
8.
Install riser, on to exhaust manifold.
9.
Make sure gasket is properly placed.
10.
Install bolts and washers to secure riser.
11.
Install any parts secured under bolts.
12.
Torque riser bolts in a crossing pattern to 40 Nm
13.
(30 ft. lb.). Make at least two passes to insure proper torque is
reached.
14.
Install all other parts mounted to risers.
15.
Install exhaust hose and secure with clamps.
16.
Connect water hose and secure with clamp.
17.
Start engine and check for fuel leaks.
Starter
Remove
1.
Disconnect power from the engine.
2.
Remove battery cable (2) from solenoid extension nut
3.
Remove solenoid extension nut (4) and cover (3) from solenoid.
4.
Remove accessory wires from solenoid (5).
5.
Remove start wire nut (6).
6.
Remove start wire from solenoid start terminal (7).
NOTICE!
GL engines have an additional purple wire attached to
the solenoid “R” terminal.
B+
1
2
3
5
4
6
7
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