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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 >> Inspection Procedure

Inspection Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Charge Air Cooler Front Manifold
    GM1644348Courtesy of GENERAL MOTORS CORP.
  1. Inspect the interior of the charge air cooler front manifold for the following:
    • Damage or restrictions to the coolant passages (1)
    • Damage to the bolt bosses (2)
    • Damage or corrosion to the gasket groove (3)
    2. Fig 2: Exterior Of Charge Air Cooler Front Manifold
    GM1644350Courtesy of GENERAL MOTORS CORP.
  2. Inspect the exterior of the charge air cooler front manifold for the following:
    • Damage to the bolt bosses (1)
    • Damage or corrosion to the gasket sealing surface (2)
    • Damage to the threaded holes (3)
    • Damage or restrictions to the coolant passages (4)
  3. Repair or replace the charge air cooler front manifold as necessary.
    4. Fig 3: Interior Of Charge Air Cooler Rear Manifold
    GM1644363Courtesy of GENERAL MOTORS CORP.
  4. Inspect the interior of the charge air cooler rear manifold for the following:
    • Damage or restrictions to the coolant passages (1)
    • Damage to the bolt bosses (2)
    • Damage or corrosion to the gasket groove (3)
    5. Fig 4: Exterior Of Charge Air Cooler Rear Manifold
    GM1644366Courtesy of GENERAL MOTORS CORP.
  5. Inspect the exterior of the charge air cooler rear manifold for the following:
    • Damage to the bolt bosses (1)
    • Damage or corrosion to the charge air cooler rear manifold (2)
  6. Repair or replace the charge air cooler rear manifold as necessary.
    7. Fig 5: Charge Air Cooler Cooling Fill Cap
    GM1644373Courtesy of GENERAL MOTORS CORP.
  7. Inspect the charge air cooler cooling fill cap for damage or corrosion (1, 2).
  8. Repair or replace the charge air cooler cooling fill cap as necessary.
    9. Fig 6: Charge Air Cooler Cooling Tube Spacers
    GM1644356Courtesy of GENERAL MOTORS CORP.
  9. Inspect the charge air cooler cooling tube spacers for damage or corrosion (1).
  10. Replace any damaged charge air cooler cooling tube spacers.
    11. Fig 7: Charge Air Cooler Cooling Tubes
    GM1644408Courtesy of GENERAL MOTORS CORP.
  11. Inspect the charge air cooler cooling tubes for the following:
    • Damaged, clogged, bent or missing fins (1)
    • Damage, corrosion or restrictions to the cooling passages (2)
    • Damage, corrosion, restrictions or missing diversion end plate (3)
    12. Fig 8: Charge Air Cooler Cooling Tubes
    GM1644411Courtesy of GENERAL MOTORS CORP.
  12. Inspect the charge air cooler cooling tubes for the following:
    • Damaged, clogged, bent or missing fins (1)
    • Damage, corrosion or restrictions to the cooling passages (2)
    • Damage, corrosion or restrictions to the intake end (3)
    13. 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.
  13. Replace any damaged, corroded or restricted charge air cooler cooling tube.
    14. Fig 9: Charge Air Cooler Housing
    GM1644401Courtesy of GENERAL MOTORS CORP.
  14. Inspect the charge air cooler housing for the following:
    • Damage to the sealing surface (1) for the charge air cooler front manifold
    • Damage to the bore (2) for the charge air cooler housing expansion plug
    • Damage to the threaded holes (3)
    • Damage to the exterior of the charge air cooler housing (4)
    • Damage to the bolt bosses (5)
    • Damage, corrosion, restrictions in the bores (6) for the charge air cooler cooling tubes
    15. Fig 10: Charge Air Cooler Housing
    GM1644402Courtesy of GENERAL MOTORS CORP.
  15. Inspect the charge air cooler housing for the following:
    • Damage to the bolt bosses (1)
    • Damage, corrosion, restrictions in the coolant passages (2)
    • Damage, corrosion, restrictions in the bores (3) for the charge air cooler cooling tubes
    16. Fig 11: Interior Of Charge Air Cooler Housing
    GM1644404Courtesy of GENERAL MOTORS CORP.
  16. Inspect the interior of the charge air cooler housing for the following:
    • Damage to the sealing grooves for the perimeter gasket (1)
    • Damage, corrosion or restrictions in the passages (2) for the charge air cooler cooling tubes
    • Damage to the sealing grooves for the interior O-ring gaskets (3)
    • Damage to the bolt bosses (4)
  17. Repair or replace the charge air cooler housing as necessary.
  18. Inspect the PCV, vacuum and pressure tubes for damage. Replace as necessary.
    19. Fig 12: Supercharger Perimeter Sealing Surface
    GM1644412Courtesy of GENERAL MOTORS CORP.
  19. Inspect the supercharger perimeter sealing surface (1) for the charge air cooler housing for damage.
    20. Fig 13: Bottom Of Supercharger
    GM1644413Courtesy of GENERAL MOTORS CORP.
  20. Inspect the bottom of the supercharger for the following:
    • Damage to the threaded holes (1)
    • Damage to the supercharger gasket sealing surface (2)
    • Damage to the throttle body gasket sealing surface (3)
    21. Fig 14: Interior Of Supercharger
    GM1644414Courtesy of GENERAL MOTORS CORP.
  21. Inspect the interior of the supercharger for the following:
    • Damage to the supercharger rotors (1)
    • Restrictions in the charge air passages (2)
    • Damage or restrictions in the passages (3) for bypass valve
    • Damage or restrictions in the intake passages (4)
    22. Fig 15: Supercharger
    GM1644415Courtesy of GENERAL MOTORS CORP.
  22. Inspect the supercharger for the following:
    • Damage or restrictions to the port (1) for the manifold absolute pressure (MAP) sensor
    • Damage or restrictions in the IAT sensor 2 threaded hole (2)
    • Damage or restrictions to the pressure port (3) for the charge air bypass regulator solenoid valve tube
    • Damage to the threaded holes (4) for the fuel rail mounting studs
    • Damage to the threaded holes (5) for the bypass actuator valve
    23. Fig 16: Supercharger
    GM1644417Courtesy of GENERAL MOTORS CORP.
  23. Inspect the supercharger for the following:
    • Damage or restrictions to the port (1) for the brake booster hose
    • Damage to the threaded hole (2) for the EVAP solenoid bolt
    • Damage or restrictions to the port (3) for the bypass actuator tube.
    • Damage or restrictions to the port (4) for the supercharger inlet absolute pressure sensor tube
    • Damage or restrictions to the port (5) for the PCV dirty air tube
    • Damage to the threaded holes (6) for the throttle body bolts
    • Damage or restrictions to the port (7) for the EVAP canister purge solenoid valve
    24. Fig 17: Bypass Valve
    GM1644419Courtesy of GENERAL MOTORS CORP.
  24. Inspect the bypass valve for the following:
    • Rotate the bypass valve to ensure the bypass valve does not bind during opening
    • Ensure the spring (1) closes the bypass valve
    25. Fig 18: Bypass Valve
    GM1644420Courtesy of GENERAL MOTORS CORP.
  25. Inspect the bypass valve (1) to ensure the valve is closing.
  26. Do NOT attempt to repair the supercharger or the bypass valve. The supercharger and bypass valve are replaced as an assembly.
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