Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

Notice: Servicing of the supercharger unit itself is limited to replacement only. No attempt should be made to disassemble the supercharger, as parts damage may result.

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
3. Remove the exhaust gas recirculation (EGR) valve heat shield (1), nut (2), and the bolt (3).
4. Remove the supercharger drive belt. Refer to Drive Belt Replacement .
5. Remove the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 3.8L.
6. Disconnect the MAP and the BARO sensor electrical connectors.
7. Disconnect the vacuum hoses from the MAP .



8. Remove the MAP and BARO sensor bracket bolts.
9. Remove the MAP and BARO sensor bracket.



10. Remove the boost control solenoid. Refer to Boost Control Solenoid Replacement in Engine Controls - 3.8L.
11. Disconnect the vacuum lines from the following:

•	Supercharger bypass valve

•	Manifold vacuum source

12. Disconnect the electrical connectors from the following:

•	Supercharger bypass valve

•	Exhaust gas recirculation (EGR) valve

•	EVAP purge valve

•	Mass air flow (MAF/IAT) sensor

•	Electronic throttle control (ETC)

13. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.8L.



14. Remove the left side supercharger bolts (1,3).



15. Remove the right side supercharger bolts (1,3).
16. Remove the supercharger.



17. Remove the supercharger gasket.



18. Remove the supercharger O-ring seals.
19. Clean the lower intake manifold-to-supercharger mating surfaces.
20. If replacing the supercharger remove the following:

•	Throttle body

•

PCV valve

•	Supercharger bypass valve

•	Manifold vacuum source

1. If replacing the supercharger install the following:

•	Manifold vacuum source

•	Supercharger bypass valve

•

PCV valve

•	Throttle body




2. Install the new supercharger O-ring seals.




Important: Do not use any sealer on the gasket.

3. Install the new supercharger gasket.



4. Install the supercharger.

Notice: Refer to Fastener Notice in the Preface section.

5. Install the right side supercharger bolts (1,3).



6. Install the left side supercharger bolts (1,3).

Tighten
Tighten the supercharger bolts starting from the center and working to the outside of the supercharger to 23 N·m (17 lb ft).

7. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.8L.
8. Connect the electrical connectors to following:

•	Electronic throttle control (ETC)

•	Mass air flow (MAF/IAT) sensor

•	EVAP purge valve

•	Exhaust gas recirculation (EGR) valve

•	Supercharger bypass valve

9. Connect the vacuum lines to the following:

•	Manifold vacuum source

•	Supercharger bypass valve

10. Install the boost control solenoid. Refer to Boost Control Solenoid Replacement in Engine Controls - 3.8L.



11. Install the MAP and BARO sensor bracket.
12. Install the MAP and BARO sensor bracket bolts.

Tighten
Tighten the bolts to 30 N·m (22 lb ft).

13. Connect the vacuum hoses to the MAP sensor.
14. Connect the MAP and the BARO sensor electrical connectors.
15. Lightly coat the fuel injectors (3) with clean engine oil.




Important: Ensure the fuel rail is fully seated in the lower intake manifold assembly.

16. Install the fuel rail assembly (1) to the lower intake assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 3.8L (L32).
17. Install the supercharger drive belt. Refer to Drive Belt Replacement .



18. Install the EGR valve heat shield (1) , nut (2) and the bolt (3).

Tighten
Tighten the nut and the bolt to 10 N·m (89 lb in).

19. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
21. Inspect for fluid or vacuum leaks.