SUPERCHARGER & CHARGE AIR COOLER



Supercharger System

CAUTION: The supercharger is not a bolt-on option. It is part of an integrated -engine system. Many components of the supercharged engine are not interchangeable with similar parts from a non-supercharged engine.

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 18 km (10 miles) or more to relearn the strategy.

NOTE: The supercharger is serviced only as an assembly. Disassembly of the supercharger may void the warranty.

The supercharger is a positive displacement pump. Its purpose is to supply an excess volume of intake air to the engine by increasing air pressure and density in the intake manifold. The supercharger is matched to the engine by its displacement and drive belt ratio, and can provide excess air flow at any engine speed.

  • The supercharger system is a blow-through type with the fuel injected directly into the intake ports.
  • The supercharger is drive belt driven off the crankshaft through an idler pulley.
  • The throttle body controls the amount of intake air to the supercharger through the inlet plenum.
  • Air from the supercharger is routed through the charge air cooler and then to the intake manifold.

    • The resulting denser air charge in the combustion chamber provides for a higher power output of the engine over a non-supercharged engine of the same displacement.

    At partial-throttle opening or when vacuum is in the intake system, a vacuum-controlled bypass valve reroutes some discharged air from the supercharger back through the intake plenum. This prevents the supercharger from cavitating, causing:

  • Reduced performance.
  • Increased temperatures.
  • Poor economy.

    • The supercharger contains two three-lobed rotors.

  • The helical shape and specialized porting provide smooth discharge flow and low level of noise during operation.
  • The rotors are supported by ball bearings in front and by needle bearings at the rear.
  • The drive gears are pressed into place so the supercharger is replaced as a unit and is not serviceable. (see Magnuson Products)

    • Charge Air Cooler

    Supercharged vehicles are equipped with a charge air cooler (CAC) mounted next to the vehicle radiator. The charge air cooler cools the pressurized air from the supercharger, increasing the air density. this improves combustion efficiency, engine horsepower and torque.

    Intake Manifold

    The lower intake manifold is a one-piece aluminum casting.

  • Runner lengths are tuned to optimize engine torque and power output.
  • The lower intake manifold provides mounting for the supercharger, fuel injection supply manifold and charge air cooler to intake manifold adapter.
  • Pockets for the fuel injectors are machined into the cylinder heads to prevent air and fuel leaks.
  • Pockets, in which the fuel injectors are mounted, are placed to direct the injector fuel spray immediately in front of each engine intake valve.

    • Boost Control

    CAUTION: Intake manifold pressure or engine power output cannot be increased by altering the bypass valve or the supercharger by ass valve actuator. Altering the bypass valve or supercharger bypass valve actuator may cause damage to engine.

    To prevent supercharger cavitation, reduced performance and increased temperatures, a vacuum controlled bypass valve is installed at the supercharger outlet. This bypass valve allows a controlled amount of air flow from the supercharger outlet back into the supercharger:

  • At low throttle, the engine runs under vacuum due to normal intake restrictions.
  • As the throttle opening increases, the supercharger bypass valve actuator closes the bypass valve, directing all air from the-supercharger to the intake manifold. This occurs as soon as the throttle opens and results in an immediate response.

    • Lubrication


    CAUTION: Prevent dirt or moisture from entering the supercharger during service or damage to engine may occur.

    The supercharger has a self-contained oiling system that does not require a fluid change for the life of the vehicle. However, at every 48,280 km (30,000 miles interval the supercharger fluid level should be checked.

    Item
    Description
    Item
    Description
    1
    Charge Air Cooler Inlet Tube
    15
    Nut
    2
    Charge Air Cooler
    16
    EGR Transducer
    3
    Supercharger Outlet Plenum
    17
    Lower Intake Manifold
    4
    Bolt (4 Req'd)
    18
    Fuel Injection Supply Manifold
    5
    Bolt
    19
    Bolt (2 Req'd)
    6
    Supercharger
    20
    Stud Bolt
    7
    Nut (4 Req'd)
    21
    Charge Air Cooler to Intake Manifold Adapter
    8
    Throttle Body
    22
    Intake Air Temperature Sensor
    9
    Supercharger Inlet Plenum Gasket
    23
    Nut (6 Req'd)
    10
    Bolt (4 Req'd)
    24
    Charge Air Cooler Outlet Tube
    11
    Gasket
    25
    Supercharger Bypass Valve Actuator Hose
    12
    Vacuum Supply Hose
    26
    Hose Clamp (2 Req'd)
    13
    Vacuum Aspirator
    27
    Supercharger Inlet Plenum
    14
    Bolt
    28
    Bolt