Automotive Manual PDF

STOCK EXHAUST SYSTEM REMOVAL
1. Remove frame cover.
2. Remove right side footpeg assembly held in place by two bolts (Figure 1).
3. Remove exhaust port nuts.
4. Remove bolts securing rear muffler to exhaust system mounting bracket.
5. Remove complete exhaust system. Begin by lifting muffler out of mounting bracket locating hole (assistance may be required).
6. Check condition of stock exhaust gaskets. Replace if damaged or worn.
7. Remove two bolts attaching stock exhaust mounting bracket to frame.
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Installing spark plugs
Torque is one of the most critical aspects of spark plug installation. Torque directly affects the spark plugs’ ability to transfer heat out of the combustion chamber. A spark plug that is under-torqued will not be fully seated on the cylinder head, hence heat transfer will be slowed. This will tend to elevate combustion chamber temperatures to unsafe levels, and pre-ignition and detonation will usually follow. Serious engine damage is not far behind.
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Ford 4.6L and 5.4L 3-valve engine cam phasers, how they work, their limitations, and how COMP uses them for making more power
What are cam phasers?
Ford’s cam phasers are specially designed, computer controlled cam gears that have the ability to adjust camshaft position while the engine is running. They are used on all 2005 and newer, 3-valve Ford modular engines. Since the modular engine uses two camshafts, one for each side of the engine, two cam phasers are used per engine.
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Previously published service information regarding camshaft sprocket bolt torque specifications for the 1.8L Volkswagen/ Audi 1.8L AEB engines may have incorrectly listed the torque value at 74 ft.lbs.

The correct torque value for the camshaft sprocket bolt is 48 ft.lbs. (65 Nm).These cylinder heads are beginning to be seen in machine shops because many miles have accumulated since they were new. If the incorrect torque value is used,the result may be engine failure.Even if the bolt does not break after over-torquing, it is possible that all engine valves (20) will bend/break if the head bolts fail while engine is running (Figure 1, left).
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