Removal And Installation; General; Engine Removal - Sea-doo GTX DI 5563 2002 Shop Manual

REMOVAL AND INSTALLATION

GENERAL

On some models, it is not necessary to remove
engine from watercraft to service TOP END, PTO
FLYWHEEL or MAGNETO. However, engine remov-
al is necessary to repair BOTTOM END.

ENGINE REMOVAL

Use the VCK (Vehicle Communication Kit) (P/N 529
035 676) and release the fuel pressure in the fuel
system. Refer to ENGINE MANAGEMENT section.
In order to remove engine from watercraft proceed
as follows.
First, disconnect battery cables from battery.
WARNING
Always disconnect battery cables exactly in
the specified order, BLACK negative cable
first then the RED positive battery cable last.
Electrical Connections
It is recommended to disconnect electrical con-
nections prior to disconnecting fuel lines.
Disconnect temperature sensor wire and spark plug
cables.
Disconnect magneto wiring harness.
1. Unplug connector
Disconnect both throttle position sensors (TPS),
manifold air pressure sensor (MAPS) and manifold
air temperature sensor (MATS).
SMR2002-060_04_03A.FM
Subsection 03 (REMOVAL AND INSTALLATION)
Disconnect connectors from fuel injectors and di-
rect injectors.
Disconnect connector from knock sensor.
Disconnect RAVE valve hose where shown. Inspect
hose. If it has hardened or is slit, replace hose.
1. Disconnect hose here
Refer to ENGINE MANAGEMENT for location of sen-
sors and connectors.
Unplug air compressor lines (inlets and outlets):
cooling, oil (outlet only) and air (inlet only on throt-
tle body side).
Disconnect vent hose from balancing shaft gear
housing.
Jet Pump Removal
To withdraw jet pump, refer to JET PUMP.
CAUTION: Whenever removing engine from
watercraft, engine/jet pump alignment must be
performed at reinstallation.
Drive System
To withdraw drive shaft(s), refer to DRIVE SYSTEM.
Cooling System
Disconnect the engine water supply hose.
Disconnect the engine water return hose.
NOTE: Engine will have to be raised inside bilge
to disconnect drain hose before removing from
bilge.
Refer to COOLING SYSTEM for proper water hose
location.
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Section 04 ENGINE (DI)
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