Sea-Doo 4-TEC Supercharged, Supercharged Intercooled, Naturally Aspirated, GTX, RXP Engine User Manual

Sea-Doo 4-TEC Supercharged, Supercharged Intercooled, Naturally Aspirated, GTX, RXP Engine User Manual

Below you will find brief information for Engine 4-TEC Supercharged, Engine 4-TEC Supercharged Intercooled, Engine 4-TEC Naturally Aspirated, Engine 4-TEC GTX. This manual provides detailed instructions on how to inspect, remove, disassemble, assemble, and install the intake system of the 4-TEC engine. The manual includes detailed diagrams and step-by-step instructions for each procedure. It also provides important safety information and warnings that should be followed during the repair process.

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Sea-Doo 4-TEC Supercharged, 4-TEC Supercharged Intercooled, 4-TEC Naturally Aspirated, 4-TEC GTX User Manual | Manualzz

INTAKE SYSTEM

4-TEC Engines

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

Oil

Loctite 243

10 N•m

(89 lbf•in)

Loctite 243

6 N•m

(53 lbf•in)

10 N•m

(89 lbf•in)

Loctite 243

Loctite 243

10 N•m

(89 lbf•in)

Loctite 243

6 N•m

(53 lbf•in)

18 N•m

(159 lbf•in)

10 N•m

(89 lbf•in)

R1503motr63S

TYPICAL

smr2004-Complete Line Up

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

4-TEC Supercharged Engines — Supercharger

R1503motr357S

186

Loctite 243

30 N•m

(22 lbf•ft)

30 N•m

(22 lbf•ft)

Loctite 5910

Loctite 243

Oil

10 N•m

(89 lbf•in)

Loctite 243

Anti-seize lubricant

Loctite 243

30 N•m

(22 lbf•ft)

Klueber isoflex

Oil

30 N•m

(22 lbf•ft) smr2004-Complete Line Up

2

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

4-TEC Supercharged Engines — Intake Manifold and Throttle Body

Loctite 243

Huile

10 N•m

(89 lbf•po)

6 N•m

(53 lbf•po)

Loctite

243

10 N•m

(89 lbf•po)

Huile

R1503motr251S smr2004-Complete Line Up

10 N•m

(89 lbf•po)

Loctite 243

6 N•m

(53 lbf•po)

18 N•m

(159 lbf•po)

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

4-TEC Supercharged Intercooled Engines

10 N•m

(89 lbf•in)

10 N•m

(89 lbf•in)

6 N•m

(53 lbf•in)

Loctite

243

Oil

Loctite

243

Loctite 243

10 N•m

(89 lbf•in)

Loctite 243

6 N•m

(53 lbf•in)

18 N•m

(159 lbf•in)

Oil

Oil

R1503motr358S

188 smr2004-Complete Line Up

4

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 result in skin burn.

NOTE: The inspection can be done while intercooler remains installed in air intake manifold.

Remove:

– seat

– outlet hose from exhaust manifold

– inlet hose from intercooler.

1 2

Otherwise, remove intercooler from manifold to spray soapy water on it. If air bubbles are present, replace the intercooler. Refer to procedures farther in this section.

Properly reinstall removed parts.

The distance between engine block and intercooler outlet hose must be 3 - 7 mm (0.12 - 0.27 in) otherwise the hose would scuff on the engine block.

F19D0DA

1. Intercooler

2. Outlet hose

3. Inlet nipple

3

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.

1

A

R1503motr364A

1. Outlet hose distance

A. 3 - 7 mm (0.12 - 0.27 in)

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 realignment requirements at reinstallation.

– LH muffler strap and slide LH muffler and exhaust pipe altogether rearwards as far as possible.

smr2004-Complete Line Up

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

Remove air intake hose from supercharger ass'y.

R1503motr224A

1

1. Supercharger ass'y

2. Air intake hose

2

Remove valve cover and install camshaft locking tool (P/N 529 035 839) to prevent camshaft rotation while checking slipping moment of supercharger. Refer to CYLINDER HEAD AND VALVES.

NOTE: Rotate supercharger nut to align camshaft holes and to allow insertion of the locking tool.

1

R1503motr244A

1

1. Torque wrench

Supercharger should start to turn at a torque between 7 to 12 N•m (62 to 106 lbf•in).

If the torque is less, remove supercharger ass'y from engine (refer to SUPERCHARGER RE-

MOVAL elsewhere in this section).

CAUTION: When removing the drive gear with the needle pins, be careful not to lose one of the 40 pins.

Loosen nut on supercharger shaft engine side.

Remove L-ring, spring washers, lock washer, ceramic washers, drive gear and needle pins by turning the supercharger ass'y upside down.

7 6 4 3 2 1

R1503motr111A

1. Camshaft locking tool

Check slipping moment counterclockwise by using a torque wrench with actual torque viewer. A mirror is useful to see the viewer.

R1503motr359A

1. Nut

2. L-Ring

3. Spring washers

4. Lock washer

5. Ceramic washers

6. Drive gear

7. Needle pins

5

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6

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

Check the wear limit on drive gear, lock washer and driven plate on supercharger shaft. Check drive gear for cracks.

A

B

C

Put spring washer package together as it is assembled on the supercharger shaft. Measure the height of the unloaded spring washer package.

R1503motr360A

A. Driven plate thickness

B. Drive gear thickness

C. Lock washer thickness

DRIVEN PLATE JOURNAL DEPTH

NEW MINIMUM

NEW MAXIMUM

SERVICE LIMIT

9.960 mm (.3921 in)

10.000 mm (.3937 in)

10.3000 mm (.4055 in)

DRIVE GEAR THICKNESS

NEW MINIMUM 11.000 mm (.4331 in)

NEW MAXIMUM

SERVICE LIMIT

11.050 mm (.4350 in)

10.500 mm (.4134 in)

LOCK WASHER THICKNESS

NEW MINIMUM 6.900 mm (.2717 in)

NEW MAXIMUM

SERVICE LIMIT

7.100 mm (.2795 in)

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: Ceramic washers are not affected by wear.

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.

R1503motr248A

A

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 section.

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

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

1

2

1

F18E0PA

1. Lift lock tab

Then proceed with the tab under the tube. Refer to the following illustration to see it.

F18E1MA

Step 1: Push tab (each side) to release

Step 2: Pull tank out

Remove vent tube support.

NOTE: Pay attention not to drop the nuts under support when removing screws.

1 2

F18E0QA

1. Other lock tab under tube

1

Unlock coolant expansion tank, pull out then move away.

F18L1GA

2

1. Vent tube support

2. Remove retaining screws

3. Pay attention to nuts underneath

3

RXP 4-TEC Models

Remove engine cover. Refer to HULL AND BODY.

All Models

Remove oil dipstick.

Pull fuel rail cover out.

Release the fuel pressure in the system, refer to

ENGINE MANAGEMENT section.

Disconnect battery cables from battery.

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8

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

WARNING

Always disconnect battery cables exactly in the specified order, BLACK negative cable first then the RED positive battery cable last.

Disconnect fuel hose connector at fuel rail.

1

2

1

2

1

1

1

R1503motr222A

4-TEC SUPERCHARGED ENGINES

1. Cut locking ties to release harness coming from vehicle

4-TEC NA (Naturally Aspirated) Engines

Unplug connectors from ignition coils, TOPS valve, OSPS, TPS, idle bypass valve, engine connector, CTS, CAPS, KS, CPS, magneto, OPS and

EGTS. See following illustrations.

1 2 3 10

R1503motr78A

Step 1: Squeeze

Step 2: Pull out

1. Supporting tabs

2. Squeeze in middle of supporting tabs, hold and pull out

Cut locking ties where shown.

9

8

7

6

1

F18D0CA

4-TEC NA (NATURALLY ASPIRATED) ENGINES

1. Cut locking ties to release harness coming from vehicle

1

R1503motr60A

4-TEC NA ENGINES

1. Ignition coils

2. TOPS

3. TPS (hidden behind throttle body)

4. Idle bypass valve

5. Engine connector

6. KS

7. CPS

8. Magneto

9. “B” Kostal connector

10. OSPS

5 4 smr2004-Complete Line Up

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

4-TEC Supercharged Engines

Unplug connectors from ignition coils, idle bypass valve, engine connector, CTS, CAPS, KS, CPS, magneto, OPS and EGTS. See following illustrations.

1

4-TEC NA Engines

NOTE: The TPS connector is hidden behind the

TOPS hose. Disconnect hose from TOPS valve then move away to access the TPS connector.

Slightly pry locking tab of connector to unlock.

1

2

R1503motr223A

2 5 4 3

4-TEC SUPERCHARGED ENGINES

1. Ignition coils

2. Idle bypass valve

3. KS

4. CPS

5. Magneto

All 4-TEC Engines

For the TOPS valve connector, refer to the following illustration.

1

R1503motr75A

1. TOPS hose disconnected and moved away

2. TPS connector

3. Slightly pry tab to unlock

All 4-TEC Engines

3

R1503motr69A

1. Push here and hold while pulling connector out

R1503motr64A

TYPICAL

1. CTS connector

194

1 smr2004-Complete Line Up

10

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

R1503motr65A

TYPICAL

1. CAPS connector

1

F18D0BA

1. Oil filter housing

2. OPS

1 2

Unplug the “B” connector from the ECM.

R1503motr66A

TYPICAL

1. EGTS connector

1

NOTE: On Supercharged models, a long screwdriver may be used to unlock the connector from the sensor.

R1503motr70A

1

1. Push this end to unlock

R1503motr71A

1. Pull here to release

smr2004-Complete Line Up

1

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

Pull the connectors for KS, CPS and magneto out of the ECM support. Refer to WIRING

DIAGRAMS section.

Disconnect KS and CPS connectors.

Cut locking ties as necessary and pull wiring harness away from intake manifold.

4-TEC NA Engines

Slacken air intake silencer collar.

Unlock throttle cable housing from throttle body.

Cable is to be detached later on.

2

1

4-TEC Supercharged Intercooled Engines

Remove the hoses connected to the intercooler.

2

1

R1503motr361A

1. Hose from intercooler to exhaust manifold (outlet nipple)

2. Hose from jet pump

All 4-TEC Engines

Remove manifold retaining screws and push the oil dipstick tube out of the manifold slot.

R1503motr72A

1. Air intake silencer collar

2. Unlock throttle cable housing

4-TEC Supercharged Engines

Remove inlet hose from throttle body.

Disconnect throttle cable from throttle body.

R1503motr59A

Lift intake manifold up to pull it out of the mounting brackets just enough to reach throttle cable end.

R1503motr252A

1. Detach hose

2. Disconnect cable

196

2 1 smr2004-Complete Line Up

12

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

R1503motr61A

1. Mounting brackets

1

4-TEC NA Engines

Detach throttle cable end from throttle body.

F18D2XA

1

1. Detach cable end from throttle body

All 4-TEC Engines

Pull intake manifold out.

R1503motr77A

TYPICAL

NOTE: The flame arrester and the intercooler (if so equipped) in the intake manifold are maintenance free.

Supercharger

4-TEC Supercharged Engines

CAUTION: Be scrupulous when working on supercharger parts.

Supercharger rotation reaches 40 000 RPM. Any modification, improper repair/assembly or damage on the parts, may result in damage of the supercharger. Strictly follow the described procedures.

Remove seat.

GTX 4-TEC Series

Remove storage basket, vent tube and its support.

Refer to REMOVAL below.

RXP 4-TEC Series

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 realignment requirements at reinstallation.

– LH muffler strap and slide LH muffler and exhaust pipe altogether rearwards as far as possible.

Remove hoses from supercharger ports.

smr2004-Complete Line Up

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

1

R1503motr224A

1. Inlet hose

2. Outlet hose

1 2

Remove retaining screws and pull out the supercharger ass'y.

R1503motr250A

1. Upper retaining screws

DISASSEMBLY

Air Intake Manifold

4-TEC Supercharged Intercooled Engines

Intercooler

Remove collar from intercooler.

R1503motr225A

1. Retaining screws

1

To remove the upper screw (not shown on the picture above), use the Torx adapter (P/N 529 035

938).

F19D0DB

1. Intercooler

2. Collar

1

2

Carefully pull intercooler out of air intake manifold.

F00B20A

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14

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

2

R1503motr362A

1. Intercooler

2. O-Ring

3. Collar

3

Supercharger

4-TEC Supercharged Engines

Take apart supercharger housing.

1 2 1

1

F00B29A

PLASTIC HAMMER

NOTE: The cap nut on the supercharger shaft has

LH threads.

Loosen cap nut (turn clockwise) on supercharger shaft turbine side while holding shaft with a retaining key (P/N 529 035 949).

F00B28A

3

1. Retaining screws

2. Housing half (intake side)

3. Housing half (engine side)

1 1

1

R1503motr228A

1. Cap nut

Remove washer, turbine, O-ring and step collar from supercharger shaft.

smr2004-Complete Line Up

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

7 6 4 3 2 1

2

3

1

4

R1503motr229A

1. Washer

2. Turhine

3. O-ring

4. Step collar

Loosen nut on supercharger shaft engine side while holding shaft with a retaining key (P/N 529

035 949).

2

5

R1503motr359A

1. Nut

2. L-ring

3. Spring washers

4. Lock washer

5. Ceramic washers

6. Drive gear

7. Needle bearings

Carefully push out supercharger shaft towards engine side by using a press.

1

F00B2BA

1. Nut

2. Retaining key

1

NOTE: There are 40 loose needle bearings under the gear. Do not reuse.

Remove L-ring, spring washers, lock washer, drive gear and needle pins by turning the supercharger ass'y upside down.

F00B2CA

1. Supercharger shaft

CAUTION: Every time when removing the supercharger shaft, both ball bearings have to be replaced.

Remove ball bearing from supercharger shaft by using a press and retaining key (P/N 529 035 949).

200 smr2004-Complete Line Up

16

1

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

2

1

F00B2DA

1. Supercharger shaft

2. Ball bearing

3. Retaining key

2 3

Screw out retaining disc with seal from housing half (engine side) by using the 4-pin socket

(P/N 529 035 948).

NOTE: It may be necessary to heat the housing with a heat gun to release the retaining disc.

R1503motr236A

1. Supercharger housing half (engine side)

2. Bearing pusher

ASSEMBLY

All 4-TEC Engines

Assembly is essentially the reverse of removal procedures. However pay particular attention to the following.

Air Intake Manifold

CAUTION: Do not modify air intake system, otherwise calibration will be affected.

Intercooler

4-TEC Supercharged Intercooled Engines

Ensure O-rings are properly installed on intercooler and apply 4-stroke oil on them to ease installation.

While properly aligning the inner end of intercooler in intake manifold, gently push intercooler until it bottoms.

Rotate intercooler to position nipples as shown.

F00B2AA

1. 4-pin socket

1

Remove ball bearing from supercharger housing half (engine side) by using a press and a suitable bearing pusher.

smr2004-Complete Line Up

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

1

2

F19D0EA

1. Intake manifold flange

2. Nipple parallel with manifold flange

NOTE: If intercooler is hard to push in, a clamp can be used to press intercooler in.

1

3

2

F19D0FA

1. Clamp

2. Plastic block between nipples

3. Plastic block

Reinstall collar.

The distance between engine block and intercooler outlet hose must be 3 - 7 mm (0.12 - 0.27 in) otherwise the hose would scuff on the engine block.

1

A

R1503motr364A

1. Outlet hose distance

A. 3 - 7 mm (0.12 - 0.27 in)

Supercharger

4-TEC Supercharged Engines

CAUTION: Every time when supercharger shaft has been removed, both ball bearings have to be replaced.

CAUTION: Both ball bearings have to be installed with cages facing supercharger impeller side.

Apply enough engine oil on ball bearing. Install ball bearing on supercharger shaft by using support plate (P/N 529 035 947) to hold bearing.

CAUTION: Ensure to position ball bearing against protrusion of support plate for the installation. This way, the installation pressure will be applied to the inner race and will not be transmitted to the bearing balls which would otherwise shorten the bearing life.

CAUTION: To install ball bearings and supercharger shaft always use a press, never use any beating force like a hammer.

202 smr2004-Complete Line Up

18

1 4

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

1 2

F00B2FA

2 3

1. Supercharger shaft

2. Ball bearing

3. Bearing support plate

4. Protrusion of support plate on this side (underneath inner race)

Apply enough engine oil on ball bearing. Press in the ball bearing in supercharger housing half (engine side), by using ball bearing support/pusher

(P/N 529 035 950).

1

F00B2IA

1. Retaining disc

2. 4-pin socket

To press supercharger shaft in housing half (engine side), properly support bearing, using support plate (P/N 529 035 947) and bearing support/pusher (P/N 529 035 950) under supercharger housing half.

2 3

F00B2EA

1. Bearing support/pusher

Mount supercharger housing half (engine side) on support plate (P/N 529 035 947).

Apply Loctite 243 on retaining disc and install it in supercharger housing half by using the 4-pin socket (P/N 529 035 948). Torque to 30 N•m (22 lbf•ft).

NOTE: If a new disc is installed, do not use any

Loctite, threadlocker is already applied.

F00B2GA

1

1. Support plate

2. Bearing support/pusher

3. Protrusion here

CAUTION: Before pressing in the supercharger shaft, be sure to properly support the inner race of ball bearing in supercharger housing half with the recommended tool. This way, the installation pressure will be applied to the inner race and will not be transmitted to the bearing balls which would otherwise shorten the bearing life.

Apply heat outside of the housing with a heat gun to expand its diameter prior to inserting the shaft.

Ensure there is no O-ring on the housing half prior to heating.

smr2004-Complete Line Up

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

Apply engine oil on supercharger shaft. Press shaft with distance sleeve together in supercharger housing half.

2 1

3

2

F00B2HA

1. Supercharger shaft

2. Distance sleeve

Apply engine oil on seal and push into retaining disc by hand.

NOTE: Always use a new oil seal when assembling the supercharger.

1

R1503motr242A

1. Oil seal

Install step collar, O-ring, supercharger impeller and washer on supercharger shaft. Apply Loctite

243 on cap nut and temporary finger tight cap nut.

NOTE: The cap nut on the supercharger shaft has a left-handed thread. The Loctite has to be applied in a small dose into the nut.

4

5

1

R1503motr229B

1. Step collar

2. O-ring

3. Supercharger impeller

4. Washer

5. Cap nut

Complete installation of supercharger shaft, engine side as follows:

CAUTION: It is of the utmost importance that all parts be absolutely clean. The compressor shaft spins at up to 45 000 RPM and any debris could cause a failure.

Install the first ceramic washer.

NOTE: On the RXP 4-TEC supercharged intercooled engine, the ceramic washers differ in their inner diameter. Install first the ceramic washer with the bigger inner diameter.

The ceramic washer with the smaller inner diameter will be installed on the lock washer side.

CAUTION: Manipulate ceramic washers with care, those parts are fragile.

IMPORTANT: Apply Kluber Isoflex grease

(P/N 293 550 021) to the inner diameter of the gear thrust surface on the shaft, ceramic washers, needle bearings shaft surface and lock washer.

CAUTION: No other grease can be used, otherwise damage to bearings will occur.

Install the 40 needle bearings on the compressor shaft.

NOTE: The 40 needle bearings comes in a wax strip with an adhesive backing.

Remove the adhesive backing.

Install the drive gear over the needle bearings.

Install the other ceramic washer.

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Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

NOTE: On the RXP 4-TEC supercharged intercooled engine, the ceramic washers differ in their inner diameter. The ceramic washer with the smaller inner diameter is installed on the lock washer side.

Install the lock washer.

Apply engine oil to the spring washers.

Position the spring washers as per illustration.

CAUTION: When installing the spring washers, take care of the exact installation direction of the washers.

1

Hold the lock washer of the supercharger shaft

(engine side) using the retaining key (P/N 529 035

949).

Tigthen the impeller cap nut to 30 N•m (22 lbf•ft).

Apply Loctite 5910 on supercharger housing sealing surface. For correct procedure refer to EN-

GINE BLOCK Installation in ENGINE section.

1

R1503motr363A

1. Spring washers

Install the L-ring on the compressor shaft.

Apply Loctite 243 on the hexagonal nut threads.

Torque to 30 N•m (22 lbf•ft).

NOTE: The L-ring will pre-load the spring washers.

R1503motr359A

1. Nut

2. L-ring

3. Spring washers

4. Lock washer

5. Ceramic washers

6. Drive gear

7. Needle bearings

7 6 4 3 2 1

5

R1503motr246A

1. Apply Loctite 5910 on sealing surface

Assemble supercharger housing halves. Apply

Loctite 243 on retaining screws and torque to

10 N•m (89 lbf•in) according to the following sequence.

4

6

8

2

1

9

7

5

3

R1503motr227B

SUPERCHARGER TIGHTENING SEQUENCE

INSTALLATION

Air Intake Manifold

All 4-TEC Engines

Ensure that all gaskets are properly installed and in a good condition.

smr2004-Complete Line Up

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

4

5 3 1

2

6

7

R1503motr62A

INTAKE MANIFOLD

1. Gaskets

1

First, position intake manifold on front mounting bracket then push manifold toward engine to then proceed with rear mounting bracket.

When installing the intake manifold, lift up the oil dipstick tube a little bit to fit in the slot of the manifold.

1

R1503motr210A

Ensure to properly route and resecure wiring harness with locking ties.

WARNING

Always check O-ring for damage such as deformation at reinstallation.

Replace the

O-ring if it is damaged.

When installing throttle cable, ensure cable is in the proper position of bracket and that cable barrel is in the proper position of throttle cam.

R1503motr59B

1. Oil dipstick tube

Apply Loctite 243 (blue) on the intake manifold screws. Torque them to 10 N•m (89 lbf•in) following the tightening sequence shown.

2

F18D2XB

4-TEC NA ENGINES

1. Cable position in bracket

2. Cable barrel position in cam

1

206 smr2004-Complete Line Up

22

Section 05 ENGINE (4-TEC)

Subsection 02 (INTAKE SYSTEM)

1

F00B20A

Ensure to install the tool perpendicularly (90°) to torque wrench to apply the proper torque to the screw.

A

F19D0CA

2

4-TEC SUPERCHARGED ENGINES

1. Cable position in bracket

2. Cable barrel position in cam

Supercharger

4-TEC Supercharged Engines

Sealing surface between supercharger and PTO housing has to be greased with Super Lube grease

(P/N 293 550 030).

F00B1UA

1

1. Tool perpendicular (90°) to torque wrench

A. 90°

CAUTION: Not installing the tool as shown will change the torque applied to the screw. Proper torque and tightening sequence are important.

After complete installation of the supercharger ass'y the slipping moment has to be rechecked.

Refer to SLIPPING MOMENT INSPECTION above in this section.

Finalizing the Installation

Readjust throttle cable and reset the TPS using the

VCK. Refer to ENGINE MANAGEMENT section.

When reinstalling exhaust system components, validate LH muffler/exhaust pipe alignment with exhaust manifold. Refer to EXHAUST SYSTEM.

R1503motr247A

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1. Super Lube grease

Install supercharger ass'y on PTO housing. Apply

Loctite 243 (blue) on the retaining screws.

Torque screws to 10 N•m (89 lbf•in).

To tighten and torque the upper screw, use the

Torx adapter (P/N 529 035 938).

smr2004-Complete Line Up

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Key Features

  • Detailed instructions on how to inspect, remove, disassemble, assemble, and install the intake system
  • Step-by-step instructions with detailed diagrams
  • Important safety information and warnings
  • Instructions for supercharger removal and assembly
  • Intercooler removal and assembly instructions
  • Air intake manifold removal and assembly procedures
  • Information on the various components of the intake system
  • Torque specifications for all fasteners
  • Instructions for adjusting the throttle cable and resetting the TPS
  • Troubleshooting tips for common problems and malfunctions

Frequently Answers and Questions

How do I check for an intercooler leak?
Perform an intercooler leak test when the engine loses performance, when there is white exhaust smoke, or when the temperature in the exhaust system is too high. To perform the leak test, remove the intercooler from the manifold and spray soapy water on it. If air bubbles are present, replace the intercooler. Refer to the procedures further in this section for proper reinstallation of removed parts.
What is the slipping moment of a supercharger?
The slipping moment is the torque required to turn the supercharger shaft when the engine is not running. This torque can be used to diagnose a slipping supercharger. To check the slipping moment, remove the air intake hose from the supercharger assembly, remove the valve cover and install a camshaft locking tool, then loosen the nut on the supercharger shaft engine side. Use a torque wrench to check the slipping moment counterclockwise. The supercharger should start to turn at a torque between 7 to 12 N•m (62 to 106 lbf•in). If the torque is less, remove the supercharger assembly from the engine.
What is the proper procedure for assembling the supercharger?
The assembly process is essentially the reverse of the removal procedure with some important considerations like the correct installation of the ball bearings, installation of the ceramic washers, and the use of Kluber Isoflex grease. Ensure that all parts are absolutely clean and use a press to install the supercharger shaft.
What is the proper tightening sequence for the intake manifold screws?
Apply Loctite 243 on the intake manifold screws and follow the tightening sequence shown in the corresponding illustration. Ensure that the tool is perpendicular (90°) to the torque wrench to apply the proper torque to the screw.

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