GM Service Manual Online
For 1990-2009 cars only

Special Tools

    • EN-47814 Supercharger Bypass Valve Actuator Setting Tool
    • EN-47833 Supercharger Service Holding Fixture

For equivalent regional tools, refer to Special Tools

Disassemble Procedure


    Object Number: 1644289  Size: SH

    Note: In order to protect and service components, on the supercharger, ensure the EN-47833 fixture is on the supercharger during the disassembly and assembly.

  1. Ensure the supercharger will spin.

  2. Object Number: 1644290  Size: SH
  3. Disconnect and remove the dirty air positive crankcase ventilation (PCV) tube from the supercharger.

  4. Object Number: 1644291  Size: SH
  5. Remove the evaporative emission (EVAP) canister purge solenoid valve bolt.
  6. Remove the EVAP canister purge solenoid valve.

  7. Object Number: 1646475  Size: SH
  8. Remove and discard the O-ring from the EVAP canister purge solenoid valve.

  9. Object Number: 1644293  Size: SH
  10. Remove the throttle body bolts.
  11. Remove the throttle body.
  12. Remove and discard the throttle body O-ring.

  13. Object Number: 1644294  Size: SH
  14. Disconnect the bypass valve actuator vacuum hose at the vacuum port of the supercharger (1).

  15. Object Number: 1644295  Size: SH
  16. Disconnect the bypass valve actuator vacuum hose at the supercharger bypass valve actuator (1).

  17. Object Number: 1644296  Size: SH
  18. Remove the bypass valve actuator vacuum hose from the supercharger.

  19. Object Number: 1644297  Size: SH
  20. Disconnect the bypass valve actuator pressure hose at the supercharger bypass valve actuator (1).
  21. Disconnect the bypass valve actuator pressure hose at the charge air bypass regulator solenoid valve (2).

  22. Object Number: 1644298  Size: SH
  23. Remove the bypass valve actuator pressure hose.

  24. Object Number: 1644300  Size: SH
  25. Disconnect the charge air bypass regulator solenoid valve pressure hose at the supercharger pressure port (1).
  26. Disconnect the charge air bypass regulator solenoid valve pressure hose at the charge air bypass regulator solenoid valve (2).

  27. Object Number: 1644302  Size: SH
  28. Remove the charge air bypass regulator solenoid valve pressure hose.

  29. Object Number: 1644303  Size: SH
  30. Remove the charge air bypass regulator solenoid valve bolt.
  31. Remove the charge air bypass regulator solenoid valve.

  32. Object Number: 1644304  Size: SH
  33. Remove the bypass valve actuator bolts.

  34. Object Number: 1644305  Size: SH
  35. Pivot the bypass valve actuator clockwise in order to remove the bypass valve actuator from the bypass valve actuator cable.

  36. Object Number: 1644312  Size: SH
  37. Align the tab on the bypass valve actuator rod with the slot in the bypass valve actuator cable end.

  38. Object Number: 1644311  Size: SH
  39. Slide the bypass valve actuator rod out of the bypass valve actuator cable.
  40. Remove the bypass valve actuator.

  41. Object Number: 1644315  Size: SH
  42. Remove the bypass valve actuator cable bracket bolts from the supercharger.

  43. Object Number: 1644316  Size: SH
  44. Slide the bypass valve actuator cable clip off of the pin on the supercharger bypass valve.

  45. Object Number: 1644320  Size: SH
  46. Remove the bypass valve actuator cable.

  47. Object Number: 1644322  Size: SH
  48. Do NOT remove the supercharger bypass valve (1) from the supercharger.

  49. Object Number: 1644338  Size: SH
  50. Remove the fuel injection fuel rail crossover tube clip.

  51. Object Number: 1644340  Size: SH
  52. Remove the intake air temperature (IAT) sensor 2 from the supercharger.

  53. Object Number: 1644343  Size: SH
  54. Do NOT remove the following supercharger components:
  55. •  Drive pulley (1)
    • Oil level plug (2)
    • Front housing (3)
    • Bearings
    • Rotors
    • Gears

    Object Number: 1644344  Size: SH
  56. Remove the charge air cooler front manifold bolts.

  57. Object Number: 1644346  Size: SH
  58. Remove the charge air cooler front manifold.

  59. Object Number: 1644347  Size: SH
  60. Remove and discard the charge air cooler front manifold gasket.

  61. Object Number: 1644351  Size: SH
  62. Remove and discard the charge air cooler cooling tube front O-rings.

  63. Object Number: 1644352  Size: SH
  64. Remove the charge air cooler cooling tube front spacers.

  65. Object Number: 1644357  Size: SH
  66. Remove the charge air cooler rear manifold bolts.

  67. Object Number: 1644359  Size: SH
  68. Remove the charge air cooler rear manifold.

  69. Object Number: 1644361  Size: SH
  70. Remove and discard the charge air cooler rear manifold gaskets.

  71. Object Number: 1644367  Size: SH
  72. Remove and discard the charge air cooler cooling tube rear O-rings.

  73. Object Number: 1644368  Size: SH
  74. Remove the charge air cooler cooling tube rear spacers.

  75. Object Number: 1644370  Size: SH
  76. Remove the charge air cooler cooling fill cap bolts.

  77. Object Number: 1644371  Size: SH
  78. Remove the charge air cooler cooling fill cap.

  79. Object Number: 1644372  Size: SH
  80. Remove and discard the charge air cooler cooling fill cap O-ring.

  81. Object Number: 1644375  Size: SH
  82. Carefully remove the inboard charge air cooler cooling tubes.
  83. The charge air cooler cooling tubes are fragile and must be placed in a protected area.

  84. Object Number: 1644381  Size: SH
  85. Carefully remove the outboard charge air cooler cooling tubes.
  86. The charge air cooler cooling tubes are fragile and must be placed in a protected area.

  87. Object Number: 1644382  Size: SH
  88. Remove the long charge air cooler bolts.

  89. Object Number: 1644383  Size: SH
  90. Remove the short charge air cooler perimeter bolts.

  91. Object Number: 1644384  Size: SH
  92. Remove the charge air cooler housing.

  93. Object Number: 1644399  Size: SH
  94. Remove and discard the charge air cooler housing perimeter gasket.
  95. Remove and discard the charge air cooler housing interior O-ring gaskets.

  96. Object Number: 1644400  Size: SH
  97. Remove and discard the charge air cooler housing expansion plug.

Cleaning Procedure

    Note: Do NOT allow any debris to enter the supercharger.

  1. Remove any old thread sealant and gasket material or sealant.
  2. Do NOT soak the supercharger, bypass valve actuator, charge air bypass regulator solenoid valve, EVAP solenoid, bypass cable or throttle body in solvent.
  3. Carefully clean the outside of the supercharger. Do NOT allow any debris or solvent to enter the inside of the supercharger. Replace the supercharger if there is any damage to the rotors.
  4. Carefully clean the outside charge air cooler cooling tube. Do NOT allow any debris to enter the inside of the tubes. Replace the tube if there are any damaged, missing or bent fins. Replace the tube if the coolant passages are blocked by debris.
  5. Clean the charge air cooler housing with solvent compatible with aluminum and the painted exterior. Clean all threaded and through holes with solvent.
  6. Clean the PCV, vacuum and pressure tubes.
  7. Warning: Refer to Safety Glasses Warning in the Preface section.

  8. Carefully dry the components with compressed air.

Inspection Procedure


    Object Number: 1644348  Size: SH
  1. Inspect the interior of the charge air cooler front manifold for the following:
  2. • Damage or restrictions to the coolant passages (1)
    • Damage to the bolt bosses (2)
    • Damage or corrosion to the gasket groove (3)

    Object Number: 1644350  Size: SH
  3. Inspect the exterior of the charge air cooler front manifold for the following:
  4. •  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)
  5. Repair or replace the charge air cooler front manifold as necessary.

  6. Object Number: 1644363  Size: SH
  7. Inspect the interior of the charge air cooler rear manifold for the following:
  8. • Damage or restrictions to the coolant passages (1)
    •  Damage to the bolt bosses (2)
    •  Damage or corrosion to the gasket groove (3)

    Object Number: 1644366  Size: SH
  9. Inspect the exterior of the charge air cooler rear manifold for the following:
  10. • Damage to the bolt bosses (1)
    •  Damage or corrosion to the charge air cooler rear manifold (2)
  11. Repair or replace the charge air cooler rear manifold as necessary.

  12. Object Number: 1644373  Size: SH
  13. Inspect the charge air cooler cooling fill cap for damage or corrosion (1, 2).
  14. Repair or replace the charge air cooler cooling fill cap as necessary.

  15. Object Number: 1644356  Size: SH
  16. Inspect the charge air cooler cooling tube spacers for damage or corrosion (1).
  17. Replace any damaged charge air cooler cooling tube spacers.

  18. Object Number: 1644408  Size: SH
  19. Inspect the charge air cooler cooling tubes for the following:
  20. • 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)

    Object Number: 1644411  Size: SH
  21. Inspect the charge air cooler cooling tubes for the following:
  22. • 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)

    Note: 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.

  23. Replace any damaged, corroded or restricted charge air cooler cooling tube.

  24. Object Number: 1644401  Size: SH
  25. Inspect the charge air cooler housing for the following:
  26. • 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

    Object Number: 1644402  Size: SH
  27. Inspect the charge air cooler housing for the following:
  28. • 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

    Object Number: 1644404  Size: SH
  29. Inspect the interior of the charge air cooler housing for the following:
  30. • 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)
  31. Repair or replace the charge air cooler housing as necessary.
  32. Inspect the PCV, vacuum and pressure tubes for damage. Replace as necessary.

  33. Object Number: 1644412  Size: SH
  34. Inspect the supercharger perimeter sealing surface (1) for the charge air cooler housing for damage.

  35. Object Number: 1644413  Size: SH
  36. Inspect the bottom of the supercharger for the following:
  37. • Damage to the threaded holes (1)
    • Damage to the supercharger gasket sealing surface (2)
    • Damage to the throttle body gasket sealing surface (3)

    Object Number: 1644414  Size: SH
  38. Inspect the interior of the supercharger for the following:
  39. • 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)

    Object Number: 1644415  Size: SH
  40. Inspect the supercharger for the following:
  41. • 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

    Object Number: 1644417  Size: SH
  42. Inspect the supercharger for the following:
  43. • 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

    Object Number: 1644419  Size: SH
  44. Inspect the bypass valve for the following:
  45. • Rotate the bypass valve to ensure the bypass valve does not bind during opening
    • Ensure the spring (1) closes the bypass valve

    Object Number: 1644420  Size: SH
  46. Inspect the bypass valve (1) to ensure the valve is closing.
  47. Do NOT attempt to repair the supercharger or the bypass valve. The supercharger and bypass valve are replaced as an assembly.

Assemble Procedure


    Object Number: 1644400  Size: SH

    Note: In order to protect and service components, on the supercharger, ensure the EN-47833 fixture is on the supercharger during the disassembly and assembly.

  1. Install the NEW charge air cooler housing expansion plug.

  2. Object Number: 1644399  Size: SH
  3. Install the NEW charge air cooler housing interior O-ring gaskets.
  4. Install the NEW charge air cooler housing perimeter gasket.

  5. Object Number: 1644384  Size: SH
  6. Install the charge air cooler housing.
  7. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1644382  Size: SH
  8. Install the long charge air cooler bolts and tighten to 10 N·m (89 lb in).

  9. Object Number: 1644383  Size: SH
  10. Install the short charge air cooler perimeter bolts and tighten to 10 N·m (89 lb in).

  11. Object Number: 1644381  Size: SH

    Note: 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.

  12. Carefully install the outboard charge air cooler cooling tubes.

  13. Object Number: 1646471  Size: SH
  14. 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.

  15. Object Number: 1646472  Size: SH
  16. Align the wide notch at a 45 degree angle up from horizontal and outboard as shown.

  17. Object Number: 1644375  Size: SH

    Note: 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.

  18. Carefully install the inboard charge air cooler cooling tubes.

  19. Object Number: 1646473  Size: SH
  20. 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.

  21. Object Number: 1646474  Size: SH
  22. Align the wide notch at a 45 degree angle up from horizontal and outboard as shown.

  23. Object Number: 1644372  Size: SH
  24. Install the NEW charge air cooler cooling fill cap O-ring.

  25. Object Number: 1644371  Size: SH
  26. Install the charge air cooler cooling fill cap.

  27. Object Number: 1644374  Size: SH
  28. Ensure the charge air cooler cooling fill cap is installed in the proper orientation.
  29. • 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

    Object Number: 1644370  Size: SH
  30. Install the charge air cooler cooling fill cap bolts and tighten to 10 N·m (89 lb in).

  31. Object Number: 1644368  Size: SH
  32. Install the charge air cooler cooling tube rear spacers.

  33. Object Number: 1644367  Size: SH
  34. Install the NEW charge air cooler cooling tube rear O-rings.

  35. Object Number: 1644361  Size: SH
  36. Install the NEW charge air cooler rear manifold gaskets.

  37. Object Number: 1644359  Size: SH
  38. Install the charge air cooler rear manifold.

  39. Object Number: 1644357  Size: SH
  40. Install the charge air cooler rear manifold bolts and tighten to 10 N·m (89 lb in).

  41. Object Number: 1644352  Size: SH
  42. Install the charge air cooler cooling tube front spacers.

  43. Object Number: 1644351  Size: SH
  44. Install the NEW charge air cooler cooling tube front O-rings.

  45. Object Number: 1644347  Size: SH
  46. Install the NEW charge air cooler front manifold gasket.

  47. Object Number: 1644346  Size: SH
  48. Install the charge air cooler front manifold.

  49. Object Number: 1644344  Size: SH
  50. Install the charge air cooler front manifold bolts and tighten to 10 N·m (89 lb in).

  51. Object Number: 1644340  Size: SH
  52. Coat the IAT sensor 2 threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent.
  53. Install the IAT sensor 2 into the supercharger and tighten to 20 N·m (15 lb ft).

  54. Object Number: 1644338  Size: SH
  55. Install the fuel injection fuel rail crossover tube clip.

  56. Object Number: 1644320  Size: SH
  57. Install the bypass valve actuator cable.

  58. Object Number: 1644315  Size: SH
  59. Install the bypass valve actuator cable bracket bolts to the supercharger and tighten to 10 N·m (89 lb in).

  60. Object Number: 1644317  Size: SH
  61. Slide the bypass valve actuator cable clip onto the pin on the supercharger bypass valve.

  62. Object Number: 1644324  Size: SH

    Note: Tool shown is the clip shipped with a new bypass valve actuator cable. The flat end of the EN-47814 tool can be used for the same purpose.

  63. Pull the retainer up on the wire above the bypass valve actuator cable clip in order to install the EN-47814 tool The EN-47814 tool must be used to set the necessary slack in the bypass valve actuator cable.
  64. Place the EN-47814 tool on the cable.

  65. Object Number: 1644327  Size: SH
  66. Ensure to eliminate the slack in the bypass valve actuator cable by pressing down on the wire retainer.

  67. Object Number: 1644311  Size: SH
  68. Install the bypass valve actuator.
  69. Align the bypass valve actuator rod to the bypass valve actuator cable.

  70. Object Number: 1644312  Size: SH
  71. Align the tab on the bypass valve actuator rod with the slot in the bypass valve actuator cable end.
  72. Slide the bypass valve actuator rod into the bypass valve actuator cable.

  73. Object Number: 1644308  Size: SH
  74. Pivot the bypass valve actuator counterclockwise in order to install bypass valve actuator.

  75. Object Number: 1644304  Size: SH
  76. Loosely install the bypass valve actuator bolts.

  77. Object Number: 1644332  Size: SH
  78. Pull up on the bypass valve actuator in order to eliminate any slack in the bypass valve actuator cable.

  79. Object Number: 1644333  Size: SH
  80. Tighten the bypass valve actuator bolts to 10 N·m (89 lb in) while maintaining proper alignment between the bypass valve actuator and the bypass valve actuator cable.

  81. Object Number: 1644336  Size: SH

    Note: Tool shown is the clip shipped with a new bypass valve actuator cable. The flat end of the EN-47814 tool an be used for the same purpose.

  82. Remove the EN-47814 tool on the bypass valve actuator cable at the bypass valve.

  83. Object Number: 1644303  Size: SH
  84. Install the charge air bypass regulator solenoid valve.
  85. Install the charge air bypass regulator solenoid valve bolt and tighten to 10 N·m (89 lb in).

  86. Object Number: 1644302  Size: SH
  87. Install the charge air bypass regulator solenoid valve pressure hose.

  88. Object Number: 1644300  Size: SH
  89. Connect the charge air bypass regulator solenoid valve pressure hose at the supercharger pressure port (1).
  90. Connect the charge air bypass regulator solenoid valve pressure hose at the upper port of the charge air bypass regulator solenoid valve (2).

  91. Object Number: 1644298  Size: SH
  92. Install the bypass valve actuator pressure hose.

  93. Object Number: 1644297  Size: SH
  94. Connect the bypass valve actuator pressure hose at the lower port of the supercharger bypass valve actuator (1).
  95. Connect the bypass valve actuator pressure hose at the lower port of the charge air bypass regulator solenoid valve (2).

  96. Object Number: 1644296  Size: SH
  97. Install the bypass valve actuator vacuum hose to the supercharger.

  98. Object Number: 1644295  Size: SH
  99. Connect the bypass valve actuator vacuum hose at the upper port of the supercharger bypass valve actuator (1).

  100. Object Number: 1644294  Size: SH
  101. Connect the bypass valve actuator vacuum hose at the center small vacuum port of the supercharger (1).

  102. Object Number: 1644293  Size: SH
  103. Install the NEW throttle body O-ring.
  104. Install the throttle body.
  105. Install the throttle body bolts and tighten to 10 N·m (89 lb in).

  106. Object Number: 1646475  Size: SH
  107. Install the NEW O-ring onto the EVAP canister purge solenoid valve.

  108. Object Number: 1644291  Size: SH
  109. Install the EVAP canister purge solenoid valve.
  110. Install the EVAP canister purge solenoid valve bolt and tighten to 10 N·m (89 lb in).

  111. Object Number: 1644290  Size: SH
  112. Install and connect the dirty air PCV tube onto the supercharger.