Section 01 ENGINES (1503 4-TEC)
Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER)
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)
Spring Washer
Put spring washer package together as it is as-
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)
ASSEMBLY
Assembly is essentially the reverse of removal
procedures. However pay particular attention to
the following.
Intake Manifold and Intercooler
Supercharged Intercooled Engine
Ensure O-rings are properly installed on intercool-
er and apply 4-stroke oil on them to ease installa-
tion.
While properly aligning the inner end of intercooler
in intake manifold, gently push intercooler until it
bottoms.
Rotate intercooler to position nipples as shown.
1
F19D0EA
2
1. Intake manifold flange
2. Nipple parallel with manifold flange
NOTE: Ifintercoolerishardtopushin,aclampcan
be used to press intercooler in.
1
F19D0FA
2
3
1. Clamp
2. Plastic block between nipples
3. Plastic block
Reinstall collar.
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.
SMR2005-033 21
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