Supercharger Replacement

Supercharger Replacement

Removal Procedure





Caution Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

Notice: Servicing of the supercharger unit itself is limited to replacement only. No attempt should be made to disassemble the supercharger, as parts damage may result.

Caution Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Remove the fuel injector sight shield.
3. Remove the exhaust gas recirculation (EGR) valve heat shield nut, bolt and heat shield.
4. Remove the supercharger drive belt.
5. Remove the right spark plug wires from the ignition control module and reposition.
6. Remove the generator brace.
7. Remove the MAP sensor bracket.





8. Relieve the fuel pressure.
9. Remove the fuel rail assembly.
10. Remove the boost control solenoid.
11. Disconnect the vacuum lines from the following:
- The fuel pressure regulator valve
- The supercharger
- The supercharger bypass valve
- The manifold vacuum source
12. Disconnect the electrical connectors from the following:
- The supercharger bypass valve
- The exhaust gas recirculation (EGR) valve
- The EVAP purge valve
- The mass air flow (MAP) sensor
- The throttle position (T/P) sensor
- The idle air control (IAC) valve
- The intake air temperature sensor (IAT)
13. Remove the accelerator and the cruise control cables with the bracket from the throttle body.
14. Remove the air inlet duct from the throttle body.





15. Remove the left side supercharger bolts.





16. Remove the right side supercharger bolts.
17. Remove the supercharger.





18. Remove the supercharger gasket.





19. Remove the supercharger O-ring seals.
20. Clean the lower intake manifold-to-supercharger mating surfaces.
21. If replacing the supercharger remove the following:
- The throttle body.
- The PCV valve.
- The supercharger bypass valve.
- The manifold vacuum source.

Installation Procedure





1. If replacing the supercharger install the following:
- The manifold vacuum source.
- The supercharger bypass valve.
- The PCV valve.
- The throttle body.
2. Install the new supercharger O-ring seals.

Important: Do not use any sealer on the gasket.





3. Install the new supercharger gasket.
4. Install the supercharger.





5. Install the right side supercharger bolts.





6. Install the left side supercharger bolts.

Notice: Refer to Fastener Notice in Service Precautions.

7. Install the supercharger bolts.
- Tighten the supercharger bolts starting from the center and working to the outside of the supercharger to 23 Nm (17 ft. lbs.).
8. Install the air inlet duct to the throttle body.
9. Install the accelerator and the cruise control cables with the bracket to the throttle body.
10. Connect the electrical connectors to following:
- The intake air temperature (IAT) sensor
- The idle air control (IAC) valve
- The throttle position (T/P) sensor
- The mass air flow (MAP) sensor
- The EVAP purge valve
- The exhaust gas recirculation (EGR) valve
- The supercharger bypass valve
11. Connect the vacuum lines to the following:
- The manifold vacuum source
- The supercharger bypass valve
- The supercharger
- The fuel pressure regulator valve
12. Install the boost control solenoid.





13. Install the fuel rail assembly.
14. Install the MAP sensor bracket.
15. Install the generator brace.
16. Install the right spark plug wires to the ignition module.
17. Install the supercharger drive belt.





18. Install the exhaust gas recirculation (EGR) valve heat shield, nut and bolt.
- Tighten the EGR heat shield nut and bolt to 10 Nm and (89 inch lbs.).
19. Install the fuel injector sight shield.
20. Connect the negative battery cable.