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Supercharger

REMOVAL AND INSTALLATION

1995-97 Millenia 2.3L (KJS) Engine

CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Relieve the fuel system pressure, and disconnect the negative battery cable.
  2. Drain the cooling system.
  3. Remove the dynamic chamber cover.
  4. Remove the charge air cooler air duct.
  5. Label and disconnect the vacuum hoses and electrical connectors from the air cleaner housing. Remove the air cleaner assembly.
  6. Remove the air and fresh air ducts.
  7. Remove the mass air flow sensor and the air intake hose from the throttle body.
  8. Remove the resonator.
  9. Remove the right-hand charge air cooler.
  10. Remove the left-hand charge air cooler.
  11. Disconnect the accelerator cable.
  12. Label and disconnect the necessary vacuum hoses from the rear of the intake manifold and EGR valve.
  13. Remove the EGR valve.
  14. Remove the air intake pipe assembly.
  15. Remove the charge air cooler pipe.
  16. Disconnect and plug the fuel supply line at the fuel rails and discard the copper crush washers. Disconnect the fuel and vacuum lines from the fuel pressure regulator.

    CAUTION
    Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher nearby. Never store fuel in an open container due to risk of fire or explosion.

  17. Disconnect and plug the coolant hoses.
  18. Remove the harness from the intake manifold.
  19. Remove the intake manifold mounting nuts and bolts in 2-3 steps, then remove the intake manifold.
  20. Label and disconnect the fuel hoses and electrical connectors from the throttle body. Remove the throttle body.
  21. Remove the drive belt from the Lysholm compressor (supercharger).
  22. Remove the mounting bolts from the Lysholm compressor, and remove the compressor from the vehicle.

    To install:

  23. Clean all gasket mating surfaces.
  24. Position the rubber shield for the Lysholm compressor onto the compressor using double sided adhesive tape. Place the compressor onto the mounting studs and tighten the mounting nuts to 14-18 ft. lbs. (19-25 Nm).
  25. Install and adjust the drive belt.
  26. Install the throttle body. Tighten the nuts and bolts to 14-18 ft. lbs. (19-25 Nm), and connect the fuel hoses and electrical connectors.
  27. Position new gaskets and install the intake manifold. Tighten the nuts and bolts in 2-3 steps, from the center to the ends, to 14-18 ft. lbs. (19-25 Nm).
  28. Install the harness onto the intake manifold.
  29. Unplug and and connect the coolant hoses.
  30. Connect the fuel and vacuum lines to the fuel pressure regulator. Connect the fuel supply line to the fuel rail, using new copper crush washers.
  31. Install the charge air cooler pipe.
  32. Position the air intake pipe assembly using new gaskets. Hand tighten the nuts and bolts in the order shown in the graphic 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).
  33. Install the EGR valve using a new gasket.
  34. Connect the vacuum hoses to the intake manifold and EGR valve.
  35. Connect and adjust the accelerator cable.
  36. Using new gaskets, position the left and right-hand charge air coolers. Hand tighten the nuts and bolts in the order shown in the graphic until the air intake pipes and charge air coolers contact the intake manifold. Verify that the rubber gaskets are not twisted or distorted. Tighten the bolts marked A to 44-78 inch lbs. (5-9 Nm). Tighten the bolts marked B to 70-95 inch lbs. (8-11 Nm), and all others, in sequence, to 14-18 ft. lbs. (19-25 Nm).
  37. Install the resonator. Tighten the nuts and bolts to 12-16 ft. lbs. (16-22 Nm)
  38. Install the air intake hose onto the throttle body. Install the mass air flow sensor.
  39. Install the fresh air and air ducts.
  40. Install the air cleaner assembly and connect the vacuum hoses and electrical connectors to the air cleaner housing.
  41. Install the charge air cooler air duct. Tighten the mounting bolts to 70-95 inch lbs. (8-11 Nm).
  42. Install the dynamic chamber cover.
  43. Connect the negative battery cable.
  44. Fill and bleed the cooling system. Run the engine and check for leaks.
 
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