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Home >> Cadillac >> 2006 >> STS Base, 3.6 7, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 22 (Engine Mechanical - 4.4L (4 Of 5)) >> Off-Vehicle Repair Instructions (Part 3) >> Supercharger Cleaning and Inspection - Off Vehicle >> Assemble Procedure

Assemble Procedure

WARNING: This page is about a different variant/trim than selected.
    IMPORTANT: In order to protect and service components, on the supercharger, ensure the EN-47833  is on the supercharger during the disassembly and assembly. See Special Tools .
    Fig 1: Charge Air Cooler Housing Expansion Plug
    GM1644400Courtesy of GENERAL MOTORS CORP.
  1. Install the NEW charge air cooler housing expansion plug.
    2. Fig 2: Charge Air Cooler Housing Interior O-Ring Gaskets
    GM1644399Courtesy of GENERAL MOTORS CORP.
  2. Install the NEW charge air cooler housing interior O-ring gaskets.
  3. Install the NEW charge air cooler housing perimeter gasket.
    4. Fig 3: Charge Air Cooler Housing
    GM1644384Courtesy of GENERAL MOTORS CORP.
  4. Install the charge air cooler housing.
    5. Fig 4: Long Charge Air Cooler Bolts
    GM1644382Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  5. Install the long charge air cooler bolts.

    Tighten:  Tighten the long charge air cooler bolt to 10 N.m (89 lb in).

    6. Fig 5: Short Charge Air Cooler Perimeter Bolts
    GM1644383Courtesy of GENERAL MOTORS CORP.
  6. Install the short charge air cooler perimeter bolts.

    Tighten:  Tighten the short charge air cooler bolt to 10 N.m (89 lb in).

    7. Fig 6: Charge Air Cooler Cooling Tubes
    GM1644381Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The charge air cooler cooling tubes are replaced as a set. If any one of the charge air cooler cooling tubes needs to be replaced, all the charge air cooler cooling tubes must be replaced in order to maintain consistent cooling of the charge air.
  7. Carefully install the outboard charge air cooler cooling tubes.
    8. Fig 7: Restrictor Plates
    GM1646471Courtesy of GENERAL MOTORS CORP.
  8. The charge air cooler cooling outboard tubes are installed with the restrictor plates (1) to the back of the manifold, away from the drive belt pulley.
    9. Fig 8: Aligning Notches At Cooler Tubes
    GM1646472Courtesy of GENERAL MOTORS CORP.
  9. Align the wide notch at a 45 degree angle up from horizontal and outboard as shown.
    10. Fig 9: Charge Air Cooler Cooling Tubes
    GM1644375Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The charge air cooler cooling tubes are replaced as a set. If any one of the charge air cooler cooling tubes needs to be replaced, all the charge air cooler cooling tubes must be replaced in order to maintain consistent cooling of the charge air.
  10. Carefully install the inboard charge air cooler cooling tubes.
    11. Fig 10: Charge Air Cooler Cooling Inboard Tubes
    GM1646473Courtesy of GENERAL MOTORS CORP.
  11. The charge air cooler cooling inboard tubes are installed with the opening (1) to the back of the manifold. The restrictor plates will be to the front of the manifold, towards the drive belt pulley.
    12. Fig 11: Aligning Notches
    GM1646474Courtesy of GENERAL MOTORS CORP.
  12. Align the wide notch at a 45 degree angle up from horizontal and outboard as shown.
    13. Fig 12: Charge Air Cooler Cooling Fill Cap O-Ring
    GM1644372Courtesy of GENERAL MOTORS CORP.
  13. Install the NEW charge air cooler cooling fill cap O-ring.
    14. Fig 13: Charge Air Cooler Cooling Fill Cap
    GM1644371Courtesy of GENERAL MOTORS CORP.
  14. Install the charge air cooler cooling fill cap.
    15. Fig 14: Charge Air Cooler Cooling Fill Cap
    GM1644374Courtesy of GENERAL MOTORS CORP.
  15. Ensure the charge air cooler cooling fill cap is installed in the proper orientation.
    • The alignment boss (1) is at the rear of the charge air cooler manifold
    • The alignment boss (2) is at the front of the charge air cooler cooling fill cap
    16. Fig 15: Charge Air Cooler Cooling Fill Cap Bolts
    GM1644370Courtesy of GENERAL MOTORS CORP.
  16. Install the charge air cooler cooling fill cap bolts.

    Tighten:  Tighten the charge air cooler cooling fill cap bolt to 10 N.m (89 lb in).

    17. Fig 16: Charge Air Cooler Cooling Tube Rear Spacers
    GM1644368Courtesy of GENERAL MOTORS CORP.
  17. Install the charge air cooler cooling tube rear spacers.
    18. Fig 17: Charge Air Cooler Cooling Tube Rear O-Rings
    GM1644367Courtesy of GENERAL MOTORS CORP.
  18. Install the NEW charge air cooler cooling tube rear O-rings.
    19. Fig 18: Charge Air Cooler Rear Manifold Gaskets
    GM1644361Courtesy of GENERAL MOTORS CORP.
  19. Install the NEW charge air cooler rear manifold gaskets.
    20. Fig 19: Charge Air Cooler Rear Manifold
    GM1644359Courtesy of GENERAL MOTORS CORP.
  20. Install the charge air cooler rear manifold.
    21. Fig 20: Charge Air Cooler Rear Manifold Bolts
    GM1644357Courtesy of GENERAL MOTORS CORP.
  21. Install the charge air cooler rear manifold bolts.

    Tighten:  Tighten the charge air cooler rear manifold bolt to 10 N.m (89 lb in).

    22. Fig 21: Charge Air Cooler Cooling Tube Front Spacers
    GM1644352Courtesy of GENERAL MOTORS CORP.
  22. Install the charge air cooler cooling tube front spacers.
    23. Fig 22: Charge Air Cooler Cooling Tube Front O-Rings
    GM1644351Courtesy of GENERAL MOTORS CORP.
  23. Install the NEW charge air cooler cooling tube front O-rings.
    24. Fig 23: Charge Air Cooler Front Manifold Gasket
    GM1644347Courtesy of GENERAL MOTORS CORP.
  24. Install the NEW charge air cooler front manifold gasket.
    25. Fig 24: Charge Air Cooler Front Manifold
    GM1644346Courtesy of GENERAL MOTORS CORP.
  25. Install the charge air cooler front manifold.
    26. Fig 25: Charge Air Cooler Front Manifold Bolts
    GM1644344Courtesy of GENERAL MOTORS CORP.
  26. Install the charge air cooler front manifold bolts.

    Tighten:  Tighten the charge air cooler front manifold bolt to 10 N.m (89 lb in).

    27. Fig 26: IAT Sensor
    GM1644340Courtesy of GENERAL MOTORS CORP.
  27. Coat the IAT sensor 2 threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent.
  28. Install the IAT sensor 2 into the supercharger.

    Tighten:  Tighten the IAT sensor 2 to 20 N.m (15 lb ft).

    29. Fig 27: Fuel Rail Crossover Tube Clip
    GM1644338Courtesy of GENERAL MOTORS CORP.
  29. Install the fuel injection fuel rail crossover tube clip.
    30. Fig 28: Bypass Valve Actuator Cable
    GM1644320Courtesy of GENERAL MOTORS CORP.
  30. Install the bypass valve actuator cable.
    31. Fig 29: Bypass Valve Actuator Cable Bracket Bolts
    GM1644315Courtesy of GENERAL MOTORS CORP.
  31. Install the bypass valve actuator cable bracket bolts to the supercharger.

    Tighten:  Tighten the bypass valve actuator cable bracket bolt to 10 N.m (89 lb in).

    32. Fig 30: Bypass Valve Actuator Cable Clip
    GM1644317Courtesy of GENERAL MOTORS CORP.
  32. Slide the bypass valve actuator cable clip onto the pin on the supercharger bypass valve.
    33. Fig 31: Locating Retainer
    GM1644324Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Tool shown is the clip shipped with a new bypass valve actuator cable. The flat end of the EN-47814  can be used for the same purpose. See Special Tools .
  33. Pull the retainer up on the wire above the bypass valve actuator cable clip in order to install the EN-47814  . See Special Tools . The EN-47814  must be used to set the necessary slack in the bypass valve actuator cable. See Special Tools .
  34. Place the EN-47814  on the cable. See Special Tools .
    35. Fig 32: Locating Retainer
    GM1644327Courtesy of GENERAL MOTORS CORP.
  35. Ensure to eliminate the slack in the bypass valve actuator cable by pressing down on the wire retainer.
    36. Fig 33: Bypass Valve Actuator
    GM1644311Courtesy of GENERAL MOTORS CORP.
  36. Install the bypass valve actuator.
  37. Align the bypass valve actuator rod to the bypass valve actuator cable.
    38. Fig 34: Bypass Valve Actuator Rod
    GM1644312Courtesy of GENERAL MOTORS CORP.
  38. Align the tab on the bypass valve actuator rod with the slot in the bypass valve actuator cable end.
  39. Slide the bypass valve actuator rod into the bypass valve actuator cable.
    40. Fig 35: Bypass Valve Actuator
    GM1644308Courtesy of GENERAL MOTORS CORP.
  40. Pivot the bypass valve actuator counterclockwise in order to install bypass valve actuator.
    41. Fig 36: Bypass Valve Actuator Bolts
    GM1644304Courtesy of GENERAL MOTORS CORP.
  41. Loosely install the bypass valve actuator bolts.
    42. Fig 37: Bypass Valve Actuator
    GM1644332Courtesy of GENERAL MOTORS CORP.
  42. Pull up on the bypass valve actuator in order to eliminate any slack in the bypass valve actuator cable.
    43. Fig 38: Bypass Valve Actuator Cable
    GM1644333Courtesy of GENERAL MOTORS CORP.
  43. Tighten the bypass valve actuator bolts while maintaining proper alignment between the bypass valve actuator and the bypass valve actuator cable.

    Tighten:  Tighten the bypass valve actuator bolt to 10 N.m (89 lb in).

    44. Fig 39: Locating Retainer
    GM1644336Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Tool shown is the clip shipped with a new bypass valve actuator cable. The flat end of the EN-47814  can be used for the same purpose. See Special Tools .
  44. Remove the EN-47814  on the bypass valve actuator cable at the bypass valve. See Special Tools .
    45. Fig 40: Charge Air Bypass Regulator Solenoid Valve
    GM1644303Courtesy of GENERAL MOTORS CORP.
  45. Install the charge air bypass regulator solenoid valve.
  46. Install the charge air bypass regulator solenoid valve bolt.

    Tighten:  Tighten the charge air bypass regulator solenoid valve bolt to 10 N.m (89 lb in).

    47. Fig 41: Charge Air Bypass Regulator Solenoid Valve Pressure Hose
    GM1644302Courtesy of GENERAL MOTORS CORP.
  47. Install the charge air bypass regulator solenoid valve pressure hose.
    48. Fig 42: Supercharger Pressure Port
    GM1644300Courtesy of GENERAL MOTORS CORP.
  48. Connect the charge air bypass regulator solenoid valve pressure hose at the supercharger pressure port (1).
  49. Connect the charge air bypass regulator solenoid valve pressure hose at the upper port of the charge air bypass regulator solenoid valve (2).
    50. Fig 43: Bypass Valve Actuator Pressure Hose
    GM1644298Courtesy of GENERAL MOTORS CORP.
  50. Install the bypass valve actuator pressure hose.
    51. Fig 44: Supercharger Bypass Valve Actuator
    GM1644297Courtesy of GENERAL MOTORS CORP.
  51. Connect the bypass valve actuator pressure hose at the lower port of the supercharger bypass valve actuator (1).
  52. Connect the bypass valve actuator pressure hose at the lower port of the charge air bypass regulator solenoid valve (2).
    53. Fig 45: Bypass Valve Actuator Vacuum Hose
    GM1644296Courtesy of GENERAL MOTORS CORP.
  53. Install the bypass valve actuator vacuum hose to the supercharger.
    54. Fig 46: Supercharger Bypass Valve Actuator
    GM1644295Courtesy of GENERAL MOTORS CORP.
  54. Connect the bypass valve actuator vacuum hose at the upper port of the supercharger bypass valve actuator (1).
    55. Fig 47: Supercharger Vacuum Port
    GM1644294Courtesy of GENERAL MOTORS CORP.
  55. Connect the bypass valve actuator vacuum hose at the center small vacuum port of the supercharger (1).
    56. Fig 48: Throttle Body
    GM1644293Courtesy of GENERAL MOTORS CORP.
  56. Install the NEW throttle body O-ring.
  57. Install the throttle body.
  58. Install the throttle body bolts.

    Tighten:  Tighten the throttle body bolt to 10 N.m (89 lb in).

    59. Fig 49: EVAP Canister Purge Solenoid Valve O-Ring
    GM1646475Courtesy of GENERAL MOTORS CORP.
  59. Install the NEW O-ring onto the EVAP canister purge solenoid valve.
    60. Fig 50: EVAP Canister Purge Solenoid Valve
    GM1644291Courtesy of GENERAL MOTORS CORP.
  60. Install the EVAP canister purge solenoid valve.
  61. Install the EVAP canister purge solenoid valve bolt.

    Tighten:  Tighten the EVAP canister purge solenoid valve bolt to 10 N.m (89 lb in).

    62. Fig 51: PCV Dirty Air Tube
    GM1644290Courtesy of GENERAL MOTORS CORP.
  62. Install and connect the dirty air PCV tube onto the supercharger.
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