Supercharger

REMOVAL & INSTALLATION

2.3L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Remove the negative battery cable.
4. Drain the cooling system.
5. Remove or disconnect the following:
   • Dynamic chamber cover
   • Charge air cooler air duct
   • Vacuum hoses and electrical connectors from the air cleaner housing
   • Air cleaner assembly
   • Fresh air ducts
   • Mass air flow sensor and the air intake hose from the throttle body
   • Resonator
   • Right-hand charge air cooler
   • Left-hand charge air cooler
   • Accelerator cable
   • Vacuum hoses from the rear of the intake manifold and Exhaust Gas Recirculation (EGR) valve
   • EGR valve
   • Air intake pipe assembly
   • Charge air cooler pipe
   • Fuel supply line at the fuel rails and discard the copper washers
   • Fuel and vacuum lines from the fuel pressure regulator
   • Coolant hoses
   • Wiring harness from the intake manifold
   • Intake manifold mounting nuts and bolts in 2–3 steps
   • Intake manifold
   • Fuel hoses and electrical connectors from the throttle body
   • Throttle body
   • Drive belt from the compressor (supercharger)
   • Mounting bolts from the compressor
   • Compressor

   To install:

6. Clean all gasket mating surfaces.
7. Position the rubber shield for the compressor onto the compressor using double sided adhesive tape.
8. Install or connect the following:
   • Compressor. Tighten the nuts to 14–18 ft. lbs. (19–25 Nm).
   • Compressor drive belt

     Fig. 1: When installing the compressor, ensure that the rubber insulating pad is temporarily affixed to the compressor

   • Throttle body. Tighten the nuts/bolts to 14–18 ft. lbs. (19–25 Nm).
   • Fuel hoses and electrical connectors
   • Intake manifold using a new gasket. Tighten the nuts/bolts in 2–3 steps, from the center to the ends, to 14–18 ft. lbs. (19–25 Nm).
   • Wiring harness onto the intake manifold
   • Coolant hoses
   • Fuel and vacuum lines to the fuel pressure regulator
   • Fuel supply line to the fuel rail using new copper crush washers
   • Charge air cooler pipe
   • Position the air intake pipe assembly using new gaskets
9. Hand-tighten the nuts/bolts in the order shown until the air intake pipe contacts the intake manifold. Verify that the rubber gaskets are not twisted or distorted. Tighten the bolts marked A to 70–95 inch lbs. (8–11 Nm) and all others, in sequence, to 14–18 ft. lbs. (19–25 Nm).
10. Install or connect the following:
    • EGR valve using a new gasket
    • Vacuum hoses to the intake manifold and EGR valve
    • Accelerator cable and adjust it
    • Left and right-hand charge air coolers using new gaskets. Hand-tighten the nuts/bolts in the order shown until the air intake pipes and charge air coolers contact the intake manifold. Verify that the rubber gaskets are not twisted or distorted.
11. Tighten the charge air cooler bolts to:
    1. Marked A: 44–78 inch lbs. (5–9 Nm)
    2. Marked B: to 70–95 inch lbs. (8–11 Nm)
    3. All others, in sequence: 14–18 ft. lbs. (19–25 Nm).
12. Install or connect the following:
    • Resonator. Tighten the nuts/bolts to 12–16 ft. lbs. (16–22 Nm).
    • Air intake hose onto the throttle body
    • Mass air flow sensor
    • Fresh air ducts
    • Air cleaner assembly
    • Vacuum hoses and electrical connectors to the air cleaner housing
    • Charge air cooler air duct. Tighten the bolts to 70–95 inch lbs. (8–11 Nm).
    • Dynamic chamber cover
    • Negative battery cable
13. Fill the cooling system.
14. Run the engine and check for leaks.