Sea-doo GTX 4-TEC 5573 2002, Shop Manual

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Section 06 ENGINE MANAGEMENT (DI)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)
SMR2002-075 _06-03A.FM
06-03-1
COMPONENT INSPECTION AND
ADJUSTMENT
0
GENERAL
Engine problems are not necessarily related to the
electronic fuel injection system.
It is important to ensure that the mechanical integrity
of the engine/propulsion system is present:
– good jet pump/drive system operation
– good engine compression and properly operat-
ing mechanical components, no leaks etc.
– fuel pump connection and fuel lines without leaks.
Check the chart in TROUBLESHOOTING section
to have an overview of problems and suggested
solutions.
When replacing a component, always check its
operation after installation.
FUEL SYSTEM
– Use the VCK (Vehicle Communication Kit) (P/N 529
035 844) to release the fuel pressure in the sys-
tem. Look in the ACTIVATION section of the soft-
ware B.U.D.S.
– Always disconnect battery properly prior to
working on the fuel system.
When the job is done, ensure that hoses from fuel
rail going to fuel pump are properly secured in their
support. Then, pressurize the fuel system. Perform
the high pressure test as explained in this section
and pressurize the fuel tank and fuel lines as ex-
plained in FUEL SYSTEM section.
Properly reconnect the battery.

WARNING
Air compressor hose may be hot. Use a rag
or gloves or let hose cool down.

WARNING
The fuel system of a fuel injection system holds
much more pressure than on a carbureted wa-
tercraft. Prior to disconnecting a hose or to re-
moving a component from the fuel system, fol-
low the recommendation described here. Pay
attention that some hoses may have more than
one clamp at their ends. Ensure to reinstall the
same quantity of clamps at assembly.

WARNING
Fuel lines remain under pressure at all times. Al-
ways proceed with care and use appropriate
safety equipment when working on pressurized
fuel system. Wear safety glasses and work in a
well ventilated area. Do not allow fuel to spill on
hot engine parts and/or on electrical connectors.
Proceed with care when removing/installing
high pressure test equipment or disconnecting
fuel line connections. Use the VCK (Vehicle Com-
munication Kit)
to release fuel pressure prior to
removing a hose. Cover the fuel line connection
with an absorbent shop rag. Slowly disconnect
the fuel hose to minimize spilling. Wipe off any
fuel spillage in the bilge. Fuel is flammable and
explosive under certain conditions. Always work
in a well ventilated area. Always disconnect bat-
tery prior to working on the fuel system. After
performing a pressure test, use the valve on the
fuel pressure gauge to release the pressure (
if so
equipped ).

WARNING
Ensure to verify fuel line connections for dam-
age and that NO fuel line is disconnected prior to
installing the safety lanyard on the DESS post.
Always perform the high pressure test if any
component has been removed. A pressure test
must be done before connecting the safety lan-
yard. The fuel pump is started each time the safe-
ty lanyard is installed and it builds pressure very
quickly.
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