Charge Air Cooler Installation - Polaris RZR XP Service Manual

CHARGE AIR COOLER INSTALLATION

1. Install new charge air cooler seal and install charge
air cooler into the intake manifold. Torque fasteners to
specification.
TORQUE
Charge Air Cooler Fasteners:
Torque in sequence to 7 ft-lb (10 Nm)
2. Carefully install the intake manifold through the
passenger side of the vehicle.
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3. Install the clamps retaining the intake manifold into
the engine. Tighten the clamps to specification.
TORQUE
Intake Manifold Clamps:
6 ft-lb (8 Nm)
9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual
© Copyright Polaris Industries Inc.
ENGINE / COOLING SYSTEM
4. Install the four fasteners retaining the throttle body to
the intake manifold. Torque fasteners to specification.
TORQUE
Throttle Body Fasteners:
7 ft-lb (10 Nm)
IMPORTANT
Ensure the gasket between the throttle body and intake
manifold is properly in place and not damaged. An
intake leak will result in poor performance.
5. Replace the crush washers on both sides of the banjo
a
fitting. Install the fastener
pressure reference hose banjo fitting. Torque fastener
to specification.
TORQUE
Manifold Pressure Fitting Bolt:
7 ft-lb (10 Nm)
o
6. Install the two fasteners
intake manifold. Torque fasteners to specification.
TORQUE
Fuel Rail Fasteners:
7 ft-lb (10 Nm)
7. Install the fasteners retaining the intake manifold to
the transmission. Torque fasteners to specification.
TORQUE
Intake Manifold Mounting Fasteners (lower):
20 ft-lb (27 Nm)
retaining the manifold air
retaining the fuel rail to the
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