Removal and Installation
SUPERCHARGER ASSEMBLY, RENEW
- Depressurize the fuel system.
- Disconnect the battery.
- Raise the vehicle on a ramp.
- Slacken the bolt securing the support strut to the cylinder block.
- Disconnect the throttle body connecting hose from the rear air duct elbow (1 Fig. 1).
- Remove the connector from the engine oil pressure sensor.
- Remove the connector from the exhaust gas recirculation temperature sensor (if fitted).
- Lower the vehicle on the ramp.
- Remove the bolt securing the support strut to the intake manifold and reposition the support strut to the rear.
- Remove the supercharger drive belt.
- Remove the bolt (6 Fig. 2) securing the engine oil dipstick tube clip to the intake manifold.
- Remove the connector from the mass air flow sensor. Release the retaining clips, remove the sensor from the air cleaner and discard the `O' ring seal.
- Disconnect the hose from the intercooler intake elbow (2 Fig. 2). Remove the elbow securing bolts (3 Fig. 2), remove the elbow and discard the `O' ring seal.
- Disconnect the servo vacuum pipe quick-fit connector. (No special tool is required).
- Disconnect the fuel rail feed and return pipe quick-fit connectors from the underfloor pipes using Service Tools JD 182 and JD 203. Fit plugs to the connectors and pipes.
- Disconnect the coolant header tank bleed hose from the intake manifold stub pipe and fit plugs to the hose and stub pipe.
- Place absorbent cloth under the intercooler coolant feed and return hoses and disconnect the hoses from the stub pipes (7 Fig. 2). Fit plugs to the hoses and stub pipes immediately to minimize coolant loss and remove the absorbent cloth.
- Remove the connectors from the oxygen sensor and starter motor link harness. Remove the engine harness earth lead eyelet from the intake manifold rear stud.
- Remove the bolts securing the injector cover to the fuel rail and remove the connectors from the fuel injectors.
- Disconnect the camshaft cover breather hose from the intake manifold stub pipe.
- Remove the bolts securing the intake manifold to the cylinder head.
- Reposition the harness connector mounting bracket away from the intake manifold.
- Withdraw the intercooler / intake manifold assembly (8 Fig. 2) from the cylinder head studs and reposition for access to the underside.
- Remove the connectors from the front and rear knock sensors, the air temperature sensor, the throttle potentiometer and the idle speed control valve.
- Reposition the harness branch and connectors between the intake manifold central ports.
- Disconnect the camshaft cover breather hose from the throttle body adapter stub pipe and reposition the hose branch between the intake manifold ports.
- Remove the intercooler / intake manifold assembly from the vehicle.
- Remove and discard the intake manifold gasket. Clean the joint faces on the cylinder head and intake manifold.
- Remove the supercharger outlet elbow/hose assembly (9 Fig. 1) from the supercharger.
- Remove the rubber gasket from the groove in the outlet elbow and discard it. Remove the `O' ring seal from the groove in the supercharger bypass valve housing (1 Fig. 2) and discard it.
- Remove the connecting hose from the throttle body.
- Working with another person:
- Open the throttle butterfly fully; carefully remove the internal bolt securing the throttle body adapter (2 Fig. 2) to the supercharger. (A mirror will aid location of the bolt). To prevent jamming carefully close the throttle butterfly.
Note: Great care must be taken to avoid damage to the throttle butterfly, spindle, or body while the bolt is being removed. A stick magnet will aid retrieval of the bolt after it has been undone.
- Working without another person:
- Remove the lower nuts and upper bolts (10 Fig. 1) securing the supercharger to the mounting casting. Displace the supercharger from the mounting casting and reposition for access.
- Remove the remaining external bolts (3 Fig. 2) securing the throttle body adapter to the supercharger. Displace the throttle body / adapter assembly from the supercharger and reposition for access.
- Remove the supercharger assembly (11 Fig. 1) from the mounting casting.
- Clean the joint faces on the supercharger, throttle body and throttle body adapter.
- Fit a new supercharger assembly (11 Fig. 1)to the mounting casting and engage on the lower securing studs.
- Fit a new gasket on the supercharger ring dowels; carefully position the throttle body/adapter assembly and engage on the dowels. Fit and tighten the external bolts (3 Fig. 2) securing the throttle body adapter to the supercharger.
- Locate the supercharger assembly on the mounting casting. Fit and tighten the upper bolts (10 Fig. 1) and lower nuts securing the supercharger to the casting.
- Working with another person:
- Open the throttle butterfly fully; carefully fit and tighten the internal bolt securing the throttle body adapter (2 Fig. 2) to the supercharger. (A mirror will aid location of the bolt). To prevent jamming, carefully close the throttle butterfly.
Note: Great care must be taken to avoid damage to the throttle butterfly, spindle, or body while the bolt is being tightened. The bolt may be held in place on the socket by using adhesive tape. Ensure that tape is not trapped by the head of the bolt during fitting.
- Working without another person:
- Connect the connecting hose to the throttle body and tighten the securing clamp.
- Lubricate and fit a new `O' ring seal to the groove in the supercharger bypass valve housing (1 Fig. 1). Fit a new rubber gasket to the groove in the supercharger outlet elbow, ensuring that the four gasket retention mouldings are properly seated in the groove.
- Fit and align the outlet elbow / hose assembly (9 Fig. 2) to the supercharger and bypass valve housing. Fit and tighten the bolts securing the outlet elbow to the supercharger.
- Fit new intake manifold to cylinder head studs.
- Place the intercooler / intake manifold assembly (8 Fig. 2) in the engine compartment but do not fit to the engine at this stage.
- Reposition the camshaft cover breather hose branch between the intake manifold ports and connect the hose to the throttle body stub pipe.
- Reposition the engine harness branch between the intake manifold central ports and fit the connectors to the front and rear knock sensors, the air temperature sensor, the throttle potentiometer and the idle speed control valve.
- Fit the intercooler / intake manifold assembly to the cylinder head. Fit and tighten the front five securing bolts.
Note: While fitting the assembly to the cylinder head ensure that the connectors are not disturbed and that no components or wiring become trapped.
- Reposition the mounting bracket for the oxygen sensor / starter link harness connector. Fit and tighten the remaining cylinder head securing bolts.
- Connect the camshaft cover breather hose to the intake manifold stub pipe and tighten the securing clamp.
- Fit the connectors to the fuel injectors. Fit and tighten the bolts securing the injector cover to the fuel rail.
- Place the engine harness earth lead eyelet on the intake manifold rear stud. Fit and tighten the securing nut. Fit the connectors to the starter motor link harness and oxygen sensor.
- Place absorbent cloth under the intercooler coolant feed and return hoses. Remove the plugs from the hoses and stub pipes (7 Fig. 2) and connect the hoses to the stub pipes immediately to minimize coolant loss. Tighten all the securing clamps. Remove the absorbent cloth.
- Remove the plugs from the coolant header tank bleed hose and the intake manifold stub pipe. Connect the hose to the stub pipe and tighten the securing clamp.
- Remove the plugs from the fuel rail feed and return pipe quick-fit connectors and the underfloor pipes and fit the connectors to the pipes.
- Connect the servo vacuum pipe quick-fit connector.
- Fit a new `O' ring seal to the intercooler intake elbow. Fit the hose to the elbow but do not tighten the securing clamp (2 Fig. 1) at this stage. Align the elbow with the inter- cooler. Fit and tighten the securing bolts (3 Fig. 1). Align and tighten the hose securing clamp.
- Fit a new `O' ring seal to the mass air flow sensor. Fit the sensor to the air cleaner, secure the retaining clamps and fit the connector to the sensor.
- Align the engine oil dipstick tube clip with the intake manifold. Fit and tighten the securing bolt (6 Fig. 1).
- Reposition the support strut. Fit and tighten the securing bolt.
- Raise the vehicle on a ramp.
- Fit the connector to the engine oil pressure sensor.
- Fit the connector to the exhaust gas recirculation temperature sensor (if fitted).
- Connect the throttle body connecting hose to the rear air duct elbow and tighten the securing clamp (1 Fig. 2).
- Tighten the bolt securing the support strut to the cylinder block.
- Lower the vehicle on the ramp.
- Fit the supercharger drive belt.
- Check the coolant level in the header tank and top up as required.
- Connect the battery.