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There is a hole in the rear cylinder jug that is leaking oil.The hole is by the rear cylinder head right below the rear exhaust. Is there a bolt that goes in this hole? The hole is 11/2 to 2 inches deep. the manual doesn't show this. I have a 1998 Kawasaki VN 1500 vulcan Classic
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Before servicing the vehicle, refer to the Precautions Section.
Drain the cooling system.
Properly relieve the fuel system pressure.
Remove or disconnect the following:
Negative battery cableExhaust manifoldAlternatorWater crossoverIntake manifoldValve coverTiming coverSecondary camshaft drive chainPower steering return hose retaining bolt from the cylinder head3 M6 external drive bolts from the front portion of the cylinder head10 M11 internal drive cylinder head boltsCylinder head and gasket.
Clean the head mating surfaces.
To install:
Fig. Left cylinder head bolt torque sequence-4.6L engine
Install the cylinder head with a new gasket. Lubricate the bolts with engine oil prior to installation.
Torque the M11 bolts in sequence as follows:
Step 1: 30 ft. lbs. (40 Nm), plus an additional 70 degrees
Step 2: Turn an additional 60 degrees
Step 3: Turn an additional 60 degrees (total 190 degrees)
Torque the M6 bolts to 106 inch lbs. (12 Nm)
Install or connect the following:
Power steering return hose retaining bolt to the cylinder head and tighten to 37 ft. lbs. (50 Nm)Secondary camshaft drive chainTiming coverValve coverIntake manifoldWater crossoverExhaust manifoldNegative battery cable
Change the oil and filter.
Fill the cooling system.
Right Side
Before servicing the vehicle, refer to the Precautions Section.
Drain the cooling system.
Properly relieve the fuel system pressure.
Remove or disconnect the following:
Negative battery cableExhaust manifoldWater crossoverIntake manifoldValve coverTiming coverSecondary camshaft drive chainElectrical connector from the Engine Coolant Temperature (ECT) sensorNut attaching the coil cassette ground wire to the cylinder headBolt attaching the exhaust crossover pipe to the cylinder headBolt attaching the right transaxle mount bracket to the cylinder headBolt attaching the rear transaxle brace to the transaxleNuts attaching the rear transaxle brace to the cylinder headRear transaxle brace3 M6 external drive bolts from the front portion of the cylinder head10 M11 internal drive cylinder head boltsCylinder head and gasket
Clean the head mating surfaces.
To install:
Fig. Right cylinder head bolt torque sequence- 4.6L engine
Install the cylinder head with a new gasket. Lubricate the bolts with engine oil prior to installation.
Torque the M11 bolts in sequence as follows:
Step 1: 30 ft. lbs. (40 Nm), plus an additional 70 degrees.
Step 2: Turn an additional 60 degrees.
Step 3: Turn an additional 60 degrees (total 190 degrees).
Torque the M6 bolts to 106 inch lbs. (12 Nm).
Install or connect the following:
Rear transaxle brace over the studs located at the rear of the right cylinder headNuts attaching the rear transaxle brace to the cylinder head, looselyBolts attaching the rear transaxle braces to the transaxle and tighten to 37 ft. lbs. (50 Nm)Nuts attaching the rear transaxle brace to the cylinder head and tighten 37 ft. lbs. (50 Nm)Electrical connector to the ECT sensorBolt attaching the exhaust crossover pipe to the cylinder head and tighten to 18 ft. lbs. (25 Nm)Nut attaching the coil cassette ground wire to the cylinder head and tighten to 13 ft. lbs. (17 Nm)Secondary camshaft drive chainTiming coverValve coverIntake manifoldWater crossoverExhaust manifoldNegative battery cable
I am assuming you are calling the cylinder the jug on the engine. If you think the engine is leaking oil from the cylinder you have to replace the crankcase. The cylinder does not separate form the crankcase as they do on atvs. If you see the leak at a gasket, it could be a blown head gasket, valve cover gasket or a sump gasket. The sump gasket is the gasket between the crankcase and the sump. The sump is the part of the engine the mounting screws thread into. The valve cover gasket is between the head and the stamped steel cover. Replacing the valve cover gasket is easy. Just remove the four bolts to remove the cover. Then clean the old gasket off. You can apply a thin layer of rtv to help seal the valve cover. The head gasket is between the cylinder and the head of the engine. If this gasket fails, the engine can burn oil and/or leak oil. The head gasket is more involved to replace. You need a set of feeler gauges and a toque wrench to do the repair
The cylinder head should be cleaned and inspected prior to installation.
Lightly oil all bolt and stud bolt threads before installation.
Clean all gasket mating surfaces thoroughly.
Install a new head gasket on the cylinder block. WARNING Always use new cylinder head bolts when installing the cylinder head or damage to the engine may occur.
Install the cylinder head on the cylinder block.
Tighten the cylinder head bolts in reverse of the removal sequence. Tighten the 2004 cylinder head bolts to 18 ft. lbs. (25 Nm). Tighten an additional 70°, plus 70°, plus another 50°. Tighten 2005 bolts to 18 ft. lbs. (25 Nm). Tighten an additional 60°, plus 60°, plus another 10°.
Install the right engine mount. Tighten the engine mount attaching bolts to 22 ft. lbs. (30 Nm).
Install or connect the following:
Intake manifold
Intake manifold support bracket. Tighten the bolts to 18 ft. lbs. (25 Nm).
Throttle cable
Surge tank coolant hose
Heater hose to cylinder head
Fuel feed line at the fuel rail
All vacuum hoses
Exhaust manifold
Rear timing belt cover
Timing belt tensioner. Tighten the bolts to 18 ft. lbs. (25 Nm).
Idler pulley. Tighten the bolts to 18 ft. lbs. (25 Nm).
Intake and exhaust camshaft gears. Tighten the bolts to 49 ft. lbs. (68 Nm).
Apply a small amount of gasket sealant to the corners of the front camshaft caps and the top of the rear camshaft cover-to-cylinder head seal.
Install the valve cover using a new gasket
Align the timing marks on the camshaft gears.
Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.
Install the timing belt and rotate the water pump clockwise to apply tension to the timing belt.
Tighten the water pump bolts to 89 inch lbs. (10 Nm).
Adjust the timing belt tension.
Install or connect the following:
Spark plug wires
Upper and lower timing belt coversCrankshaft pulley. Tighten the bolt to 70 ft. lbs. (95 Nm), plus an additional 30°, then another 15°.
Remove distributor to spark plug wires (12286) using Spark Plug Wire Remover T74P-6666-A.
Disconnect muffler inlet pipe.
If equipped with secondary air injection, disconnect the secondary air injection check valve tube (9B480).
Remove attaching bolts and right exhaust manifold (9430).
Inspect joint faces for signs fo exhaust leaks, cracks or any defect that would make exhaust manifold unfit for use
Left-Hand Removal
1. Remove oil level indicator tube (6754).
Remove spark plug heat shield.
Remove distributor to spark plug wires using Spark Plug Wire Remover T74P-6666-A.
Disconnect EGR valve to exhaust manifold tube (9D477). If equipped with air injection, disconnect the secondary air injection check valve tube.
Disconnect muffler inlet pipe.
Remove attaching bolts and exhaust manifold (9431).
Inspect joint faces for signs of exhaust leaks, cracks or any defect that would make the exhaust manifold unfit for use.
Installation
Clean mating surfaces of right exhaust manifold or left exhaust manifold and cylinder head (6049). Clean mounting flange of right exhaust manifold or left exhaust manifold and inlet pipe(s). Clean mounting surface for air injection tube or right exhaust manifold. Apply light film of Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B to right exhaust manifold or left exhaust manifold.
Position right exhaust manifold or left exhaust manifold on cylinder head. Install attaching bolts and washers, starting at fourth bolt hole from front of each right exhaust manifold or left exhaust manifold. Tighten bolts to 34-47 Nm (25-35 lb-ft), working from center right to both ends.
Position inlet pipes to right exhaust manifold or left exhaust manifold. Install attaching nuts and tighten to 34-47 Nm (25-35 lb-ft).
Position the secondary air injection check valve tube and the secondary air injection tube gasket (9C435) at rear of right-hand exhaust manifold. Install attaching bolts and tighten to 19-25 Nm (14-18 lb-ft).
Attach the secondary air injection manifold tube (9B449) to left-hand exhaust manifold fitting (located under EGR tube). Tighten nut to 30-40 Nm (22-30 lb-ft).
Attach the secondary air injection check valve tube to rear of right-hand cylinder head. Tighten bolts to 75-85 Nm (56-62 lb-ft).
Connect EGR valve to exhaust manifold tube to left exhaust manifold, if removed. Tighten nut to 53-72 Nm (39-53 lb-ft).
Install spark plug heat shield and distributor to spark plug wires.
Install oil level indicator tube to left exhaust manifold, if removed. Tighten nut to 13-24 Nm (10-18 lb-ft).
Either the cylinder head is cracked or, Is it possible that a stud had once been broken off in the hole(s) and when they were drilled out the drill went a bit to deep and punctured the cylinder head? That is about the only reason their would be oil coming out of the manifold stud holes as the holes are not connected internally to anything.
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