Supercharger: Service and Repair

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.

1. Disconnect the negative battery cable. Service and Repair

2. Remove the fuel injector sight shield. Fuel Injector Sight Shield Replacement

3. Remove the exhaust gas recirculation (EGR) valve heat shield nut, bolt and the heat shield.

4. Remove the supercharger drive belt. Service and Repair

5. Remove the right spark plug wires from the ignition control module and reposition. Service and Repair

6. Remove the generator brace. Generator Brace Replacement

7. Remove the MAP sensor bracket. Service and Repair






8. Relieve the fuel pressure. Fuel Pressure Relief Procedure

9. Remove the fuel rail assembly. Service and Repair

10. Remove the boost control solenoid. Service and Repair

11. Disconnect the vacuum lines from the following:
- Fuel pressure regulator valve
- Supercharger
- Supercharger bypass valve
- Manifold vacuum source

12. Disconnect the electrical connectors from the following:
- Supercharger bypass valve
- Exhaust gas recirculation (EGR) valve
- EVAP purge valve
- Mass air flow (MAF) sensor
- Throttle position (T/P) sensor
- Idle air control (IAC) valve
- 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 cleaner intake duct.






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:
- Throttle body
- PCV valve
- Supercharger bypass valve
- Manifold vacuum source

Installation Procedure






1. If replacing the supercharger install the following:
- Manifold vacuum source
- Supercharger bypass valve
- PCV valve
- 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.






Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Install the right side supercharger bolts.





6. Install the left side supercharger bolts.
- Tighten the supercharger bolts starting from the center and working to the outside of the supercharger to 23 Nm (17 ft. lbs.).

7. Install the air cleaner intake duct.

8. Install the accelerator and the cruise control cables with the bracket to the throttle body.

9. Connect the electrical connectors to following:
- Intake air temperature (IAT) sensor
- Idle air control (IAC) valve
- Throttle position (T/P) sensor
- Mass air flow (MAP) sensor
- EVAP purge valve
- Exhaust gas recirculation (EGR) valve
- Supercharger bypass valve

10. Connect the vacuum lines to the following:
- Manifold vacuum source
- Supercharger bypass valve
- Supercharger
- Fuel pressure regulator valve
11. Install the boost control solenoid.






12. Install the fuel rail assembly.

13. Install the MAP sensor bracket.

14. Install the generator brace.

15. Install the right spark plug wires to the ignition control module.

16. Install the supercharger drive belt.






17. Install the EGR valve heat shield, nut and the bolt.
- Tighten the nut and the bolt to 10 Nm (89 inch lbs.).

18. Install the fuel injector sight shield.

19. Connect the negative battery cable. Service and Repair

20. Inspect for fluid or vacuum leaks.