PHOTO A
ENGINE REMOVAL / INSTALLATION
3.12004 Four Stroke PWC Service Manual
Engine Removal and Installation
Several sub--systems must be removed before the engine can be extracted from the engine bay. These systems
are:
S Intercooler and associated air intake hoses and components.
S Engine electrical harness.
S Oil storage tank assembly.
S Air intake and throttle body assembly.
S Heat exchanger mounting bracket and coolant--to--fresh water heat exchanger.
S Lubrication and cooling hoses.
S Exhaust pipe and manifold, with turbocharger unit.
S Pump assembly.
The use of an engine hoist or overhead crane system is required to both remove and install the engine assembly.
W ARNING
Always disconnect the positive (RED) and negative (BLACK) battery cables from the battery after removing the
engine oil and prior to performing any engine work. Failure to do so may cause severe injury or death.
NOTE: The use of an engine hoist is strongly recommended for working on and removing the en-
gine from the engine compartment. Place masking tape around the engine compartment -- seat mat-
ing surface. Doing so will prevent nicking and scratching of the hull when the engine is removed.
1. Remove the engine oil from the engine. Reference CHAPTER 2.
2. Remove the engine coolant. Reference CHAPTER 2.
3. Remove the pump nozzles and pump stator
assemblies. Pull the driveshaft and rear drive couple
away from the engine drive coupler . Reference
CHAPTER 6. (Photo A)
NOTE: Not all electrical connections can be discon-
nected without removing hoses, pipes or sub--sys-
tems. As components are removed, disconnect any
electrical connections.
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