Section 05 ENGINE (4-TEC)
Subsection 02 (INTAKE SYSTEM)
INSPECTION
Intercooler Leak Test
4-TEC Supercharged Intercooled Engines
Perform intercooler leak test when engine looses
performance, when there is white exhaust smoke
or when temperature in exhaust system is to high.
WARNING
Let engine cool down prior to perform leak
test. Direct contact with hot engine may re-
sult in skin burn.
NOTE: The inspection can be done while inter-
cooler remains installed in air intake manifold.
Remove:
– seat
– outlet hose from exhaust manifold
– inlet hose from intercooler.
1
F19D0DA
2
3
1. Intercooler
2. Outlet hose
3. Inlet nipple
Plug intercooler inlet nipple.
Install an adapter on the outlet hose to connect
the leak test pump (P/N 529 021 800).
Pressurize the intercooler to 69 kPa (10 PSI) for a
minimum of 10 minutes.
If there is a pressure drop, first spray hoses and
adapters with a soapy solution to ensure they are
not leaking.
Otherwise, remove intercooler from manifold to
spray soapy water on it. If air bubbles are present,
replace the intercooler. Refer to procedures far-
ther in this section.
Properly reinstall removed parts.
The distance between engine block and intercool-
er outlet hose must be 3 - 7 mm (0.12 - 0.27 in) oth-
erwise the hose would scuff on the engine block.
1
R1503motr364A
A
1. Outlet hose distance
A. 3-7mm(0.12-0.27in)
Supercharger Slipping Moment
Inspection
4-TEC Supercharged Engines
Remove seat.
GTX 4-TEC Series
Remove storage basket, vent tube and its support.
Refer to REMOVAL below.
RXP 4-TEC Models
Remove engine cover. Refer to HULL AND BODY.
All Models
Refer to EXHAUST SYSTEM section and remove
the following components.
– Cross-over hose from LH muffler.
– Detach exhaust pipe from exhaust manifold but
keep exhaust pipe coupled with LH muffler.
This will reduce exhaust pipe and muffler re-
alignment requirements at reinstallation.
– LH muffler strap and slide LH muffler and ex-
haust pipe altogether rearwards as far as possi-
ble.
smr2004-Complete Line Up 189
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