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Removal Procedure

WARNING: This page is about a different car, the 2004 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
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.
NOTE: 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. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L26)  or Fuel Injector Sight Shield Replacement (L32) .
  3. Remove the exhaust gas recirculation (EGR) valve heat shield (1), nut (2), and the bolt (3).
    4. Fig 1: EGR Valve Heat Shield, Nut & Bolt
    GM912661Courtesy of GENERAL MOTORS CORP.
  4. Remove the supercharger drive belt. Refer to Drive Belt Replacement (L26)  or Drive Belt Replacement (L32) .
  5. Remove the fuel rail assembly. Refer to Fuel Rail Assembly Replacement (L26) or Fuel Rail Assembly Replacement (L32) in Engine Controls - 3.8L.
  6. Disconnect the MAP and the BARO sensor electrical connectors.
  7. Disconnect the vacuum hoses from the MAP.
  8. Remove the MAP and BARO sensor bracket bolts.
    9. Fig 2: MAP & BARO Sensor Bracket Bolts
    GM1210601Courtesy of GENERAL MOTORS CORP.
  9. Remove the MAP and BARO sensor bracket.
  10. Remove the boost control solenoid. Refer to Boost Control Solenoid Replacement in Engine Controls - 3.8L.
    11. Fig 3: Boost Control Solenoid
    GM910930Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the vacuum lines from the following:
    • 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/IAT) sensor
    • Electronic throttle control (ETC)
  13. Remove the air cleaner intake duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.8L.
  14. Remove the left side supercharger bolts (1,3).
    15. Fig 4: Left Side Supercharger Bolts
    GM911155Courtesy of GENERAL MOTORS CORP.
  15. Remove the right side supercharger bolts (1,3).
    16. Fig 5: Right Side Supercharger Bolts
    GM911157Courtesy of GENERAL MOTORS CORP.
  16. Remove the supercharger.
  17. Remove the supercharger gasket.
    18. Fig 6: Identifying Supercharger Gasket
    GM190548Courtesy of GENERAL MOTORS CORP.
  18. Remove the supercharger O-ring seals.
    19. Fig 7: Supercharger O-Ring Seals
    GM190547Courtesy of GENERAL MOTORS CORP.
  19. Clean the lower intake manifold-to-supercharger mating surfaces.
  20. If replacing the supercharger remove the following:
    • Throttle body
    • PCV valve
    • Supercharger bypass valve
    • Manifold vacuum source
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