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ENGINE / COOLING SYSTEM
CHAPTER 3
ENGINE / COOLING SYSTEM
GENERAL INFORMATION............................................................................... 3.4
SPECIAL TOOLS ...................................................................................... 3.4
ENGINE LUBRICATION SPECIFICATIONS ............................................................ 3.4 3
OIL PRESSURE TEST................................................................................. 3.5
OIL FLOW CHART .................................................................................... 3.6
ENGINE SERVICE SPECIFICATIONS .................................................................. 3.7
ENGINE SPECIFICATIONS............................................................................ 3.7
ENGINE TORQUE SPECIFICATIONS.................................................................. 3.9
INTAKE / EXHAUST SYSTEM ..........................................................................3.11
INTAKE / TURBO SYSTEM OVERVIEW ..............................................................3.11
ENGINE AIR INTAKE ASSEMBLY VIEW ..............................................................3.12
AIR BOX REMOVAL ..................................................................................3.13
AIR BOX INSTALLATION .............................................................................3.13
EXHAUST ASSEMBLY VIEW .........................................................................3.14
MUFFLER REMOVAL ................................................................................3.15
MUFFLER INSTALLATION............................................................................3.15
EXHAUST PIPE REMOVAL...........................................................................3.16
HEAD PIPE / TURBO REMOVAL .....................................................................3.18
HEAD PIPE / TURBO INSTALLATION.................................................................3.19
EXHAUST PIPE INSTALLATION ......................................................................3.21
TURBOCHARGER SERVICE .........................................................................3.22
TURBOCHARGER INSPECTION ................................................................3.22
ACTUATOR / WASTEGATE INSPECTION .......................................................3.25
ACTUATOR POD REMOVAL ....................................................................3.26
OIL DRAIN TUBE SERVICE .....................................................................3.27
WASTEGATE FLAPPER INSPECTION ..........................................................3.28
P1234 BOOST REFERENCE CODE TROUBLESHOOTING...........................................3.28
COOLING SYSTEM .....................................................................................3.30
COOLING SYSTEM FLOW ...........................................................................3.30
COOLING SYSTEM SPECIFICATIONS ...............................................................3.31
COOLING SYSTEM PRESSURE TEST ...............................................................3.31
CHARGE AIR COOLER REMOVAL ...................................................................3.32
CHARGE AIR COOLER INSTALLATION ..............................................................3.34
RADIATOR REPLACEMENT..........................................................................3.36
THERMOSTAT REPLACEMENT......................................................................3.37
WATER PUMP SERVICE .............................................................................3.38
ENGINE SERVICE ......................................................................................3.41
STARTER MOTOR REMOVAL........................................................................3.41
STARTER MOTOR INSTALLATION ...................................................................3.42
FRONT ENGINE MOUNT ISOLATOR REPLACEMENT................................................3.43
CRANKSHAFT PTO SEAL REPLACEMENT ..........................................................3.44
9930583 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.1
© Copyright Polaris Industries Inc.
