Engine Mechanical - 8.1 Liter 1. Clean the gasket mounting surfaces on both the riser and the manifold 2. Use spray on gasket remover to remove ALL traces of riser gas- ket. Heavy scrapping with tools on gasket surfaces may gouge surface, preventing proper seal. 3. Follow pre-cautions on can of gasket remover to prevent damage to paint on manifold, riser or engine. zaus 4. Use 80 grit sandpaper and a sanding block, or equivalent to smooth the gasket mounting surfaces on the riser and manifold Dy Caution! Do not use rotary power sanding tools, they may leave a circular gouge in the surtace. 5. Remove all paint, coatings, gasket material, rust and anything else that will create high or low spots on the surface. 6. Each area/section of gasket mounting surface (see example in pic- ture) should be flat and smooth to a tolerance of 0.1mm. 7. Ifthe surface can not be cleaned or sanded to this tolerance, the part must be machined flat at the gasket mounting surface. 8. 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 (0.001259 in.) Roughness Average 9. Ifthe surface can not be machined to these specifications the part must be replaced VPA 7743378 10-2004 165Engine Mechanical - 8.1 Liter Exhaust Manifold Installation 1. Install the exhaust manifold studs into the cylinder head (if neces- sary) Tighten the exhaust manifold studs to 20 Nm (15 ft. b.) Install the NEW exhaust manifold gasket. 4, Install the exhaust manifold Install the exhaust manifold nuts and center bolt. + Tighten the exhaust manifold centre bolt to 35 Nm (26 ft Ib.) * Tighten the exhaust manifold nuts to 16 Nm (12 ftIb.). Install the spark plugs. Tighten the spark plugs to 20 Nm (15 ft. b.) 166 VPA 7743378 10-2004