Section 05 ENGINE (4-TEC)
Subsection 02 (INTAKE SYSTEM)
Check the wear limit on drive gear, lock wash-
er and driven plate on supercharger shaft. Check
drive gear for cracks.
A
R1503motr360A
B
C
A. Driven plate thickness
B. Drive gear thickness
C. Lock washer thickness
DRIVEN PLATE JOURNAL DEPTH
NEW MINIMUM 9.960 mm (.3921 in)
NEW MAXIMUM
10.000 mm (.3937 in)
SERVICE LIMIT 10.3000 mm (.4055 in)
DRIVE GEAR THICKNESS
NEW MINIMUM
11.000 mm (.4331 in)
NEW MAXIMUM 11.050 mm (.4350 in)
SERVICE LIMIT 10.500 mm (.4134 in)
LOCK WASHER THICKNESS
NEW MINIMUM 6.900 mm (.2717 in)
NEW MAXIMUM
7.100 mm (.2795 in)
SERVICE LIMIT 6.600 mm (.2598 in)
Replace worn parts by new ones. A clutch repair
kit is available. If all parts are within specifications,
replace the 40 needle bearings and spring washer
package on supercharger shaft.
NOTE: Ceramicwashersarenotaffectedbywear.
For assembly, refer to SUPERCHARGER ASSEM-
BLY elsewhere in this section.
Spring Washer Height
Remove supercharger ass'y from engine.
Loosen nut on supercharger shaft engine side.
Remove L-ring and spring washers from shaft.
Putspringwasherpackagetogetherasitisas-
sembled on the supercharger shaft. Measure the
height of the unloaded spring washer package.
A
R1503motr248A
A. Spring washer package height
SPRING WASHER PACKAGE HEIGHT
NEW
10.500 mm (.4134 in)
SERVICE LIMIT 9.700 mm (.3819 in)
For reassembly of the supercharger refer to SU-
PERCHARGER ASSEMBLY elsewhere in this sec-
tion.
Properly reinstall removed parts.
REMOVAL
All 4-TEC Engines
Air Intake Manifold
Remove seat and storage basket (if applicable).
GTX 4-TEC Series
Disconnect vent tube as follows.
Lift lock tab and holding the tab, pull the tube to
release it.
smr2004-Complete Line Up 191
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