ENGINE - SUPERCHARGER SUPERCHARGERww2.justanswer.com/uploads/skyvisions/2008-02-22_201117_94prev… · 2008-02-22 · 4. INSPECT SUPERCHARGER PRESSURE (a) Using a 3-way connector,

SUPERCHARGERON-VEHICLE INSPECTION1. INSPECT SUPERCHARGER OIL LEVELHINT: With the engine cold, check the oil level on the dip-stick.

(a) Park the vehicle on a level spot and turn the engine off.(b) 4WD:

Remove the LH front suspension support member.(c) 4WD:

Remove the shift cable stay.(d) Turn the yellow-headed supercharger oil level dipstick

counterclockwise and pull it out.(e) Wipe the dipstick with a clean rag.(f) Reinsert the dipstick. Turn it fully clockwise or the read-

ing will not be correct.(g) Remove the dipstick again and look at the oil level on

the end.(h) The oil level should be between the ”L” and ”F” marks

on the dipstick.If low, check for leakage and ACV, and add oil up tothe ”F” mark as follows.

(i) Add supercharger oil though the dipstick tube using avinyl tube and syringe.

Supercharger oil:Part No. 08885-80108 or equivalent

(j) Recheck the oil level.HINT: The supercharger could be damaged if it is overfilledor the oil level is low.

(k) 4WD:Reinstall the LH front suspension support member.

(l) 4WD:Reinstall the shift cable stay.

2. INSPECT MAGNETIC CLUTCH(a) Check that the magnetic clutch goes ON when the

throttle valve is opened during engine idling at the”D” position.

(b) Using an ohmmeter, measure the resistance of thestator coil between the clutch lead wire terminals.

Standard resistance:3.4 - 3.8 � at 20�C (68�F)

If the resistance is not as specified, replace the clutch stator.3. INSPECT STALL TEST

(See page AT-88 )

-ENGINE SUPERCHARGEREG-45

4. INSPECT SUPERCHARGER PRESSURE(a) Using a 3-way connector, install SST (turbocharger

pressure gauge) to the hose between the intakemanifold to the fuel pressure regulator.SST 09992-00241

(b) Check the supercharger pressure with a stall test.Standard pressure:27 kPa (0.28 kg/cm 2, 4.0 psi) or more

If the pressure is less than that specified, inspect the super-charger and supercharger bypass valve.


COMPONENTS FOR REMOVAL ANDINSTALLATION



(See Components for Removal and Installation)

1. DISCONNECT NEGATIVE (-) TERMINAL CABLEFROM BATTERYCAUTION: Work must be started after 90 seconds from thetime the ignition switch is turned to the “LOCK”position and the negative (-) terminal cable is discon-nected from the battery.

2. DRAIN ENGINE COOLANT3. REMOVE AIR DUCT4. REMOVE ENGINE COOLANT RESERVOIR AND

BRACKET5. REMOVE AIR DAMPER CASE6. REMOVE BLOWER

(b) Stretch the belt and remove the 4 nuts of the fluid cou-pling.

(c) Pull out the fan with fluid coupling.

7. DISCONNECT PS RESERVOIRRemove the 2 bolts and disconnect the PS reservoir.

8. REMOVE RADIATOR(a) Remove the 4 screws and No.2 fan shroud.

SUPERCHARGER REMOVAL


(g) Disconnect the A/T oil cooler hoses.HINT:• Be careful as some oil will leak. Catch it in a suitable container.• Plug the pipe to prevent oil from escaping.

(h) Disconnect the radiator outlet hose.

(i) Disconnect the radiator inlet hose.(j) Disconnect the water bypass hose for the throttle

body.

(d) Disconnect the ACV connector.(e) Disconnect the 3 air hoses from the ACV.(f) Remove the No.1 engine under cover.

9. REMOVE THROTTLE BODY(a) Disconnect the accelerator cable.

(k) Remove the 2 bolts, 2 supports and radiator.


(c) Remove the air cleaner hose.(1) Disconnect the A/C idle-up air hose.(2) Disconnect the ventilation tube.(3) Disconnect the air connector vent pipe.(4) Loosen the 2 clamps and remove the air cleanerhose.

(e) Disconnect the following hoses:(1) Air hose from air connector vent pipe(2) Water bypass hose from ventilation tube(3) Vacuum hose #1 from air pipe(4) Vacuum hose #2 from air pipe

(d) Disconnect the throttle position sensor and IAC valveconnectors.

(f) Remove the 4 bolts, throttle body and gasket.

(b) Disconnect the 4 air cleaner clips.


10. REMOVE DRIVE BELT FOR GENERATOR ANDPS PUMP

Loosen the No.1 idler pulley nut and adjusting bolt, and re-move the drive belt.

12. REMOVE DRIVE BELT FOR SUPERCHARGERLoosen the No.2 idler pulley nut and adjusting bolt, andremove the drive belt.

(c) Remove the 5 bolts, pump stay and PS pump with thehoses attached.

11. REMOVE PS PUMP(a) Disconnect the 2 PS idle-up hoses.

(b) Remove the bolt and PS hose clamp.


(b) Disconnect the brake booster hose.(c) Disconnect the A/C idle-up air hose.(d) Disconnect the supercharger magnetic clutch connec-

tor.(e) Disconnect the supercharger magnetic clutch connec-

tor from the No.1 hose support bracket.

14. REMOVE NO.1 AIR INLET DUCTW/ SUPERCHARGER BYPASS VALVE(a) Disconnect the supercharger bypass valve connector.

13. REMOVE NO.2 IDLER PULLEYRemove the nut, plate, idler pulley and spacer.

(g) Remove the air hoses and 3-way.

(f) Remove the 2 bolts and No.1 hose support bracket.


15. REMOVE NO.1 IDLE-UP PIPE(a) Remove the bolt holding the pipe to the equipment

drive housing.(b) Disconnect the air hose and remove the pipe.

(i) Remove the 5 nuts and No.1 air inlet duct with super-charger bypass valve.

(j) Remove the supercharger bypass valve and No.1 airinlet duct gaskets.

16. DISCONNECT NO.1 AIR TUBELoosen the clamp and disconnect the air tube from theNo.1 air outlet duct.

(h) Remove the 2 bolts and 2 nuts holding the super-charger bypass valve to the No.1 air outlet duct.

17. REMOVE NO.1 INTAKE AIR CONNECTOR BRACKETRemove the 2 bolts and bracket.


(b) Remove the 6 nuts holding the supercharger to theNo.1 air outlet duct.

(c) Separate the supercharger and No.1 air outlet duct andremove the gasket.

(d) Remove the supercharger and No.1 air outlet duct.

18. REMOVE SUPERCHARGER(a) Remove the 2 bolts and 2 nuts holding the supercharg-

er to the equipment drive housing.


COMPONENTS FOR DISASSEMBLYAND ASSEMBLY


SUPERCHARGER DISASSEMBLY

(See Components for Disassembly and Assembly)

1. DRAIN SUPERCHARGER OILRemove the magnetic plug under the rear cover and drainthe oil.

4. REMOVE CLUTCH STATOR(a) Disconnect the connector from the clamp.(b) Using snap ring pliers, remove the snap ring.(c) Remove the clutch stator.

3. REMOVE CLUTCH PULLEY(a) Using SST, remove the ring nut.

SST 09814-22010(b) Remove the clutch pulley and shim.

2. REMOVE CLUTCH HUBUsing SST, remove the nut, clutch hub and shim.SST 09504-00011

5. REMOVE CLUTCH FLANGERemove the 5 bolts and clutch flange.


8. REMOVE REAR PLATE(a) Mount the supercharger in a soft jaw vise.(b) Secure the bolt and remove the nut. Remove the 2

nuts.

6. REMOVE FRONT COVERRemove the 3 bolts, wire clamp, front cover and gasket.

7. REMOVE REAR COVERRemove the 8 bolts, rear cover and gasket.

9. IF NECESSARY, REMOVE ELBOW10. IF NECESSARY, REMOVE UNIONS

(c) Remove the 2 bolts and rear plate.


1. INSTALL REAR PLATE(a) Remove any packing material and be careful not to drop

oil on the contacting surfaces of the rear plate andhousing.

(b) Apply engine oil to the 4 locations on the uppersurface of the rotor.

(c) Apply a light coat of adhesive to the outer edge of thegroove on the side matching the rear plate.

Adhesive:Part No. 08833-00090, THREE BOND 1131,LOCTITE 518 or equivalentNOTICE: Do not apply the sealant too liberally or it willoverflow the groove in the housing and be squeezedinside the housing.

HINT: The groove in the housing is to prevent adhesive beingsqueezed inside housing.

(d) Install the rear plate as soon as the adhesive is applied.(e) Install and torque the 2 bolts.Torque: 4.9 N-m (50 kgf-cm, 43 in.-lbf)

SUPERCHARGER COMPONENTSINSPECTION1. INSPECT HOUSINGCheck that there is no damage on the inside surface of thehousing.2. INSPECT ROTORS

(a) Check that there is no damage on the outside of therotors.

(b) Check that there is no looseness in the rotors andshafts and that the rotors rotate smoothly.

3. INSPECT BEARINGSCheck that the bearings are not rough or worn.

SUPERCHARGER ASSEMBLY

(See Components for Disassembly and Assembly)


3. INSTALL HOUSING FRONT COVER(a) Remove the grease inside the housing front cover.(b) Pour supercharger grease into the housing from cover.Grease:Part No. 08887-80109 or equivalentGrease capacity:0.5 - 1.5 g (0.02 - 0.05 oz.)

2. INSTALL REAR COVERInstall a new gasket and the rear cover with the 8bolts.

Torque: 5.9 N-m (60 kgf-cm, 52 in.-Ibf)

(c) Install a new gasket, the housing front cover and wireclamp with the 3 bolts.

Torque: 5.9 N-m (60 kgf-cm, 52 in.-lbf)

(f) Mount the supercharger in a soft jaw vice.(g) Secure the bolt and install the nut. Install the 2 nuts.Torque: 49 N-m (500 kgf-cm, 36 ft-lbf)

4. INSTALL CLUTCH FLANGEInstall the clutch flange with the 5 bolts.



8. INSPECT AND ADJUST AIR GAP OF MAGNETICCLUTCH(a) Set up a dial indicator as shown in the illustration.(b) Place matchmarks to ensure that the positions of the

pulley and clutch hub remain unchanged.(c) Apply battery voltage between the terminals of the

connector, and measure the movement of the clutchhub.

7. INSTALL CLUTCH HUB(a) On the shaft install the shim used previously, then

install the clutch hub.(b) Using SST, install and torque the nut.

SST 09504-00011Torque: 31 N-m (316 kgf-cm, 23 ft-lbf)

6. INSTALL CLUTCH PULLEY(a) Install the clutch pulley.(b) Using SST, install the ring nut.

SST 09814-22010Torque: 24 N-m (245 kgf-cm, 18 ft-lbf)

5. INSTALL CLUTCH STATOR(a) Align the hole of the clutch flange with the protrusion

of the clutch stator.

(b) Using snap ring pliers, install the snap ring, facing thetaper side toward the front.


NOTICE: When measuring, check that the location marksfor the pulley and clutch hub are in the correct position.

HINT: If the air gap is greater than specification, use a thin-ner shim. If the air gap is less than specification, use athicker shim.9. INSTALL ELBOW

(a) Apply a light coat of adhesive to the part of the partof the elbow to be inserted into the housing.

Adhesive:Part No. 08833-00090, THREE BOND 1131,LOCTITE 518 or equivalent

HINT: Take measurements starting from the second time theclutch hub is operated.

(d) Measure the other 3 locations using the same method.Use the average value of the 4 locations for the airgap value.

Standard air gag:0.35 - 0.65 mm (0.0138 - 0.0256 in.)

If the air gap is not within specification, replace the shim.

(b) Using pliers and a hammer, tap in the elbow so thatit faces the same way as in the illustration.

Adjusting shim thickness mm (in.)


11. FILL WITH SUPERCHARGER OIL(a) Clean and install the magnetic plug with a new gasket.(b) Fill the supercharger with new oil.Supercharger oil:Part No. 08885-80108 or equivalentOil capacity:130 cm3 (7.9 cu in.)

10. INSTALL UNIONSUsing a hammer, tap the union into place with a block ofwood, etc., placed between the union and the hammer.

(c) Install the supercharger to the equipment drive hous-ing with the 2 bolts and 2 nuts.

Torque: 37 N-m (375 kgf-cm, 27 ft-lbf)

(b) Assemble the No.1 air outlet duct and superchargerwith a new gasket and 6 nuts.


SUPERCHARGER INSTALLATION

(See Components for Removal and Installation)

1. INSTALL SUPERCHARGER(a) Place the No.1 air outlet duct in position as shown.


5. INSTALL NO.1 AIR INLET DUCTW/ SUPERCHARGER BYPASS VALVE(a) Install 2 new supercharger bypass valve and No.1 air

inlet duct gaskets in position.(b) Install the No. 1 air inlet duct with supercharger by-

pass valve with the 5 nuts.Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf)

4. INSTALL NO.1 IDLE-UP PIPE(a) Connect the air hose to the supercharger.(b) Install the pipe to the equipment drive housing with

the bolt.Torque: 7.5 N-m (80 kgf-cm, 69 in.-lbf)

(c) Install the supercharger bypass valve with the 2 boltsand 2 nuts.

Torque: 5.4 N-m (55 kgf-cm, 48 in.-Ibf)

2. INSTALL NO.1 INTAKE AIR CONNECTOR BRACKETInstall the bracket with the 2 bolts.

Torque: 18 N-m (185 kgf-cm, 13 ft-lbf)

3. CONNECT NO.1 AIR TUBEConnect the air tube to the No.1 air outlet duct with theclamp.


(e) Install the No. 1 hose support bracket with the 2 bolts.Torque: 7.5 N-m (80 kgf-cm, 69 in.-lbf)

(f) Connect the supercharger magnetic clutch connector.(g) Connect the supercharger magnetic clutch connector

to the No.1 hose support bracket.

6. INSTALL NO.2 IDLER PULLEYTemporarily install the spacer, idler pulley and plate with thenut.

(h) Connect the brake booster hose.(i) Connect the A/C idle-up air hose.

(j) Connect the supercharger bypass valve connector.

(d) Install the air hoses and 3-way.


7. INSTALL AND ADJUST DRIVE BELT FORSUPERCHARGER

Install and adjust the drive belt with the adjusting bolt andNo.2 idler pulley nut.

Drive belt tension:New belt170 ± 10 lbfUsed belt125 ± 10 lbf

9. INSTALL AND ADJUST DRIVE BELT FORGENERATOR AND PS PUMP

Install and adjust the drive belt with the adjusting bolt andNo.1 idler pulley nut.

Drive belt tension:New belt170 ± 10 lbfUsed belt125 ± 10 lbf

8. INSTALL PS PUMP(a) Install the PS pump and stay with the 5 bolts.Torque:Long bolt48 N-m (490 kgf-cm, 35 ft-lbf)Short bolt36 N-m (370 kgf-cm, 27 ft-Ibf)

(b) Install the PS hose clamp with the bolt.Torque: 11.5 N-m (120 kgf-cm, 9 ft-lbf)

(c) Connect the 2 PS idle-up hoses.


(d) Install the air cleaner hose.(1) Install the air cleaner hose with the 2 clamps.(2) Connect the A/C idle-up air hose.(3) Connect the ventilation tube.(4) Connect the air connector vent pipe.

(b) Connect the following hoses:(1) Air hose to air connector vent pipe(2) Water bypass hose to ventilation tube(3) Vacuum hose #1 to air pipe(4) Vacuum hose #2 to air pipe

10. INSTALL THROTTLE BODY(a) Install a new gasket and throttle body with the 4 bolts.Torque: 18 N-m (185 kgf-cm, 13 ft-lbf)

(c) Connect the throttle position sensor and IAC valveconnectors.

(e) Install the 4 air cleaner clips.


11. INSTALL RADIATOR(a) Place the radiator in position, and install the 2 sup-

ports with the 2 bolts.Torque: 18 N-m (185 kgf-cm, 13 ft-lbf)

(b) Connect the water bypass hose for the throttle body.(c) Connect the radiator inlet hose.

(d) Connect the radiator outlet hose.(e) Connect the A/T oil cooler hoses(f) Install the No.1 engine under cover.

(g) Connect the 3 air hoses to the ACV.(h) Connect the ACV connector.

(f) Connect the accelerator cable.


13. INSTALL BLOWER14. INSTALL AIR DAMPER CASE15. INSTALL ENGINE COOLANT RESERVOIR AND

BRACKET16. INSTALL AIR DUCT17. FILL WITH ENGINE COOLANT18. CONNECT NEGATIVE (-) TERMINAL CABLE TO

BATTERY19. START ENGINE AND CHECK FOR COOLANT

BATTERY

(i) Temporarily install the fluid coupling w/ cooling fan withthe 4 nuts.

(j) While pressing down on the generator drive belt,torque the 4 nuts for the coupling.

Torque: 13.5 N-m (135 kgf-cm, 10 ft-lbf)

12. INSTALL PS RESERVOIRInstall the PS reservoir with the 2 bolts.

Torque: 12.5 N-m (130 kgf-cm, 9 ft-lbf)

(k) Install the No.2 fan shroud with the 4 bolts.


Documents

ENGINE - SUPERCHARGER SUPERCHARGERww2.justanswer.com/uploads/skyvisions/2008-02-22_201117_94prev… · 2008-02-22 · 4. INSPECT SUPERCHARGER PRESSURE (a) Using a 3-way connector,