Supercharger Assembly

CAUTION: Before any supercharger service, clean areas around supercharger assembly. Cover openings of the engine and supercharger while supercharger is removed to prevent damage by foreign material.

NOTE: The supercharger is serviced by replacement only.

Supercharger Removal/Assembly:

REMOVAL
1. Disconnect battery ground cable.
2. Remove throttle body air inlet tube.
3. Remove cowl vent screens.
4. Partially drain cooling system.
5. Disconnect RH side plug wires at coil assembly, and position out of the way. Disconnect electrical connections at the air bypass valve, throttle position sensor and air charger temperature sensors.
6. Disconnect vacuum lines from the inlet/plenum assembly. Remove EGR transducer from bracket and disconnect vacuum line. Disconnect PCV tube.
7. Disconnect throttle linkage at throttle housing. Remove linkage bracket attaching bolts and position bracket out of the way. Disconnect speed control (if equipped).
8. Remove two EGR valve attaching bolts and move EGR valve away from intake assembly so equipped).
9. Disconnect coolant hoses from throttle body.
10. Remove supercharger drive belt.

Supercharger Removal/Installation:

11. Remove intercooler inlet and outlet tubes.
12. Remove three intake elbow retaining bolts.
13. Remove three supercharger retaining bolts.
14. Lift supercharger and intake elbow assembly from vehicle as a unit.

Supercharger Assembly Removal/Installation:

INSTALLATION
1. Clean and inspect all gasket surfaces.
2. Position new gasket on intake manifold using guide pins, if available.
3. Install supercharger, throttle body and intake elbow as an assembly.
4. Tighten two 8mm bolts to 20-30 Nm (15-22 lb-ft). Tighten 12mm bolt to 70-95 Nm (52-70 lb-ft).
5. Install three intake elbow retaining bolts. Tighten to 26-38 Nm (20-28 lb-ft).

Intercooler:

6. Install intercooler tubes as outlined in INLET TUBE and OUTLET TUBE.

Supercharger Drive Belt:

7. Install supercharger drive belt.
8. Connect coolant hoses to throttle body.

EGR Valve Installation:

9. Connect EGR valve with new gasket to supercharger inlet elbow (if equipped). Tighten retaining bolts to 20-30 Nm (15-22 lb-ft).
10. Install throttle linkage bracket and connect throttle linkage. Tighten to 15-20 Nm (10-15 lb-ft).
11. Connect vacuum lines to inlet assembly. Connect vacuum line to EGR transducer and install transducer in bracket. Connect PCV tube.
12. Install RH plug wires. Connect electrical connectors at air bypass valve, throttle position sensor and air charge temperature sensor.
13. Install cowl covers.
14. Install throttle body air inlet tube.
15. Refill coolant to proper level.
16. Connect battery ground cable.
17. START engine and check for proper operation and leaks using propane.