GM Bonneville/Eighty Eight/LeSabre 1986-1999

Supercharger

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REMOVAL & INSTALLATION



3.8L (VIN 1) Engine
1992-95 Vehicles

See Figure 1

  1. Properly relieve the fuel system pressure, as outlined in Fuel System of this repair guide.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the accessory drive belt from the supercharger pulley.
  6.  
  7. Remove the fuel injector sight shield.
  8.  
  9. Disconnect the fuel pipes from the fuel rail.
  10.  
  11. Tag and disconnect any necessary vacuum hoses.
  12.  
  13. Detach the electrical connectors from the fuel injectors.
  14.  
  15. Remove the electrical harness shield and electrical harness from the front of the supercharger.
  16.  
  17. Remove the fuel rail mounting bolts. Remove the fuel rail with the injectors intact.
  18.  
  19. Tag and detach the electrical connectors at the Idle Air Control (IAC) valve, Throttle Position (TP) sensor, Mass Air Flow (MAF) sensor, EGR, boost control solenoid and engine coolant temperature sensor. Lay the wiring harness aside.
  20.  
  21. Remove the air intake duct from the throttle body, and remove the EGR pipe from the supercharger.
  22.  
  23. Disconnect the throttle and the cruise control cables.
  24.  
  25. Remove the boost pressure manifold and vacuum block.
  26.  
  27. Remove the cable bracket.
  28.  
  29. Remove the tensioner bracket-to-supercharger mounting stud. The stud must be removed, or the supercharger cannot be lifted high enough to clear the supercharger from the lower intake locator pins. This could cause parts damage. To remove the stud, use a stud removal tool or jam nut procedure. The jam nut procedure consists of the following:
    1. Tighten two 8mm nuts together on the stud.
    2.  
    3. Remove the stud by placing the wrench on the inner nut, then turn counterclockwise.
    4.  

  30.  
  31. Remove the throttle body from the supercharger.
  32.  
  33. Unfasten the supercharger-to-intake manifold bolts, then remove the supercharger from the intake manifold. Remove the supercharger gasket and coolant passage O-rings. Clean the intake manifold and supercharger mating surfaces. Check that the locator pins are in the proper positions, as shown in the accompanying figure.
  34.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the supercharger mounting - 1992-95 vehicles

To install:
  1. Before installing the supercharger, remove the tensioner bracket-to-supercharger stud.
  2.  
  3. Replace the coolant passage O-rings and the supercharger gasket. Do NOT use any sealer on the gasket!
  4.  
  5. Place the supercharger in position, then install the bolts finger-tight.
  6.  
  7. Install the tensioner bracket-to-supercharger stud. Tighten the bolts and stud as follows:
    1. 1992-93 vehicles: Tighten to 4 ft. lbs. (26 Nm).
    2.  
    3. 1994-95 vehicles: Tighten the stud to 88 inch lbs. (10 Nm) and the bolts to 4 ft. lbs. (26 Nm).
    4.  

  8.  
  9. If equipped, install the tensioner bracket nut and tighten to 37 ft. lbs. (50 Nm).
  10.  
  11. Install the throttle body and gasket. Tighten the throttle body retainers to 11 ft. lbs. (15 Nm).
  12.  
  13. Install the boost pressure manifold. Install the vacuum block, with a new gasket and tighten the retainers to 62 inch lbs. (7 Nm).
  14.  
  15. Install the cable bracket and connect the throttle and cruise control cables.
  16.  
  17. Connect the EGR pipe to the supercharger and install the air intake duct.
  18.  
  19. Attach the electrical connectors to the IAC, TPS, MAF, EGR, boost control solenoid and engine coolant temperature sensor.
  20.  
  21. Install the fuel rail and retaining bolts. Tighten the bolts to 15 ft. lbs. (24 Nm).
  22.  
  23. Attach the fuel injector electrical connectors.
  24.  
  25. Connect the vacuum hoses, as tagged during removal.
  26.  
  27. Connect the fuel pipes to the fuel rail.
  28.  
  29. Install the electrical harness and shield to the front the of the supercharger.
  30.  
  31. Install the accessory drive belt on the supercharger pulley.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Start the engine and check for leaks and/or noise.
  36.  

1996-99 Vehicles

See Figures 2, 3, 4 and 5

  1. Properly relieve the fuel system pressure, as outlined in Fuel System of this repair guide.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. Remove the engine cover.
  6.  
  7. Remove the air duct.
  8.  
  9. Remove the supercharger belt, as outlined in General Information & Maintenance of this repair guide.
  10.  
  11. Tag and disconnect the right side spark plug wires from the ignition module, then position them aside.
  12.  
  13. Remove the alternator brace (with the purge solenoid, if equipped).
  14.  
  15. For 1997-99 vehicles, disconnect the EGR wiring harness and remove the EGR wiring harness shield.
  16.  
  17. Detach the electrical connectors from the fuel injectors.
  18.  
  19. Remove the MAP sensor bracket.
  20.  
  21. Unfasten the fuel rail mounting bolts, then remove the fuel rail and the injectors, as an assembly.
  22.  
  23. Remove the boost control solenoid, as follows:
    1. Disconnect the boost source and signal hose from the solenoid.
    2.  
    3. Detach the electrical connector.
    4.  
    5. Unfasten the retaining nut, then remove the boost control solenoid.

      Click image to see an enlarged view

      Fig. Fig. 2: Remove the boost control solenoid

    6.  

  24.  
  25. For 1997-99 vehicles, remove the accelerator control cable bracket with the cables.
  26.  



Click image to see an enlarged view

Fig. Fig. 3: On some vehicles, you must remove the accelerator control cable bracket, along with the cables

  1. Unfasten the throttle body nuts and remove the throttle body.
  2.  



Click image to see an enlarged view

Fig. Fig. 4: Remove the throttle body-to-supercharger retainers, then remove the throttle body

Make sure to make note of the supercharger retainer positions for installation.

  1. Remove the supercharger retainers (bolts, studs and spacers), then remove the supercharger from the vehicle. Remove and discard the gasket, then thoroughly clean the gasket mating surfaces.
  2.  



Click image to see an enlarged view

Fig. Fig. 5: The supercharger retainers must be installed in the same positions from which they were removed

To install:
  1. Install a new supercharger-to-intake gasket. Do NOT use any sealer on the gasket.
  2.  
  3. Position the supercharger over the gasket, then secure using the retaining bolts. Tighten the bolts to 2 ft. lbs. (23 Nm).
  4.  
  5. Install the MAP sensor bracket. Tighten the retaining bolts to 22 ft. lbs. (30 Nm).
  6.  
  7. Position the throttle body to the supercharger and install the retaining nuts. Tighten to 89 inch lbs. (10 Nm).
  8.  
  9. For 1997-99 vehicles, install the accelerator control cable bracket with the cables attached. Secure with the retaining bolts/screws.
  10.  
  11. Install the boost control solenoid, as follows:
    1. Install the boost control solenoid to the bypass actuator bracket.
    2.  
    3. Install the retaining nut and tighten to 72 inch lbs. (8 Nm).
    4.  
    5. Attach the electrical connector.
    6.  
    7. Connect the boost vacuum source and signal hose.
    8.  

  12.  
  13. Install the fuel rail, install the retaining nuts/bolts and stud. Tighten the retaining nuts/bolts to 89 inch lbs. (10 Nm) and the stud to 3 ft. lbs. (25 Nm). Connect the fuel lines and attach the electrical connectors.
  14.  
  15. Install the alternator brace, with the purge solenoid, if equipped. Tighten the retainers to 22 ft. lbs. (30 Nm).
  16.  
  17. Install the EGR wiring harness shield bolt/screw and nut. Tighten the bolt/screw to 89 inch lbs. (10 Nm) and the nut to 89 inch lbs. (10 Nm). Attach the EGR wiring harness.
  18.  
  19. Connect the right side spark plug wires to the ignition module, as tagged during removal.
  20.  
  21. Install the supercharger belt.
  22.  
  23. Install the engine cover, then connect the negative battery cable.
  24.  
  25. Start the engine and check for leaks and proper operation.
  26.  

 
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