engine, rotax 1503 4-tec - Sea-Doo.net

Section 01 ENGINES (1503 4-TEC)Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER)INSPECTION (PARTSASSEMBLED)Intercooler Leak TestSupercharged Intercooled EnginePerform intercooler leak test when engine loosesperformance, when there is white exhaust smokeor when temperature in exhaust system is to high. WARNINGLet engine cool down prior to perform leaktest. Direct contact with hot engine may resultin skin burn.NOTE: The inspection can be done while intercoolerremains installed in intake manifold.Remove:– outlet hose from exhaust manifold– inlet hose from intercooler.Pressurize the intercooler as follows:PRESSURE TEST529 021 80069 kPa (10 PSI) for 10 minutes minIf there is a pressure drop, first spray hoses andadapters with a soapy solution to ensure they arenot leaking.Otherwise, remove intercooler from manifold tospray soapy water on it. If air bubbles are present,replace the intercooler. Refer to procedures fartherin this section.Properly reinstall removed parts.The distance between engine block and intercooleroutlet hose must be 3 - 7 mm (0.12 - 0.27 in) otherwisethe hose would scuff on the engine block.smr2005-033-007_a1. Intercooler2. Outlet hose3. Inlet nipplePlug intercooler inlet nipple.Install an adapter on the outlet hose to connectthe leak test pump (P/N 529 021 800).1R1503motr364AA1. Outlet hose distanceA. 3-7mm(0.12 - 0.27 in)10 SMR2005-033