Inspection (Parts Assembled) - SeaDoo Rotax 1503 4-Tec 2005 Engine Shop Manual

Section 01 ENGINES (1503 4-TEC)
Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER)
INSPECTION (PARTS
ASSEMBLED)
Intercooler Leak Test
Supercharged Intercooled Engine
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 re-
sult in skin burn.
NOTE: The inspection can be done while inter-
cooler remains installed in intake manifold.
Remove:
– outlet hose from exhaust manifold
– inlet hose from intercooler.
smr2005-033-007_a
1. Intercooler
2. Outlet hose
3. Inlet nipple
Plug intercooler inlet nipple.
Install an adapter on the outlet hose to connect
the leak test pump (P/N 529 021 800).
10
Pressurize the intercooler as follows:
PRESSURE TEST
69 kPa (10 PSI) for 10 minutes min
If there is a pressure drop, first spray hoses and
adapters with a soapy solution to ensure they are
not leaking.
Otherwise, remove intercooler from manifold to
spray soapy water on it. If air bubbles are present,
replace the intercooler. Refer to procedures far-
ther in this section.
Properly reinstall removed parts.
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.
1. Outlet hose distance
A. 3 - 7 mm (0.12 - 0.27 in)
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SMR2005-033