ENGINE DISASSEMBLY / ASSEMBLY
4.4
2004 Four Stroke PWC Service Manual
Engine Specific Fasten er Torque Specifications
Component FT. LBS. Nm Notes Fastener(s)
Water Pump Cover
7 10 Loctite 577
M6 x 20
M6 x 30
M6 x 35
Engine Coolant Outlet Manifold 7 10 M6 x 20
Engine Coolant Outlet Manifold Plug 7 10
Turbocharger Coolant Return Banjo
Bolt
Expansion Tank Fasteners 7 10 M6 x 20
Engine Coolant Outlet Manifold -- to --
Expansion Tank Nozzle
7 10
Turbocharger / Intercooler Specific Fastener Torque Specifications
Component FT. LBS. Nm Notes Fastener(s)
Segments 7 10 M6 x 16
Compressor Housing Clamping Lugs 7 10 M6 x 12
Oil Return Flange 7 10 M6 x 16
Turbocharger Lower Crankcase
Bracket
17 24 M8 x 40
Turbocharger Bracket -- to -- Manifold 17 24 M8 x 50
Wastegate Actuator Locknut 7 10
Wastegate Bracket -- to -- Manifold 7 10 Torx E 8
Wastegate -- to -- Bracket 7 10 M6
Actuator Arm -- to -- Lever 7 10 M6 x 20
Intercooler Cover 6 9 M6 x 20
Intercooler Mounting Fasteners 7 10 M6 x 35
Intake Manifold Specific Fastener Torque Specifications
Component FT. LBS. Nm Notes Fastener(s)
Airbox / Screen Arrestor Fastener 6 9 M6 x 20
Manifold -- to -- Lower Bracket 7
13
10
18
M6 x 25
M8 x 60
Manifold -- to -- Cylinder Head 7 10 M6 x 30
Lower Bracket -- to -- Lower Crankcase 22 30 M8 x 30
Manifold Drain Fitting 11 15 Loctite 603
Alternator Assembly Specific Fastener Torque Specifications
Component FT. LBS. Nm Notes Fastener(s)
Magnet Rotor Fastener 73 100 M12 x 90
Cable Clamp 3 4 Loctite 272 M4 x 6
Sprague Clutch 7 10 Loctite 272 M6 x 16
Stator Fasteners 7 10 M6 x 35
Stator Cover 7 10 M6 x 20
M6 x 25
M6 x 65
Regulator Fasteners 7 10 M6 x 30