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Supercharger Replacement
 
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Pelican Technical Article:

Supercharger Replacement

Steve Vernon

Time:

1 hour1 hr

Tab:

$1,800 to $4,500

Talent:

****

Tools:

Serpentine belt tool, 16mm, 13mm wrench, 13mm, 10mm, 8mm socket, extensions, flathead screwdriver, pliers

Applicable Models:

R53 (2002-06)

Parts Required:

Supercharger, gaskets

Hot Tip:

Use care handling the fins on the intercooler

Performance Gain:

Horse power

Complementary Modification:

Coolant flush

Grinding noises from your supercharger are a sure sign that it is starting to fail and no amount of hoping is going to make it heel itself. The supercharger is partially cooled and lubricated by oil within the housing that needs maintenance and if this is a surprise to you than there is a good chance the oil has failed and the supercharger will need to be replaced. The supercharger works on very tight tolerances and even with proper care will eventually wear out.

Replacing the supercharger is not an easy or quick job, but if you follow the procedures laid out here and in the other articles you will need to reference, you will be fine.

Over the years your car may have been serviced by multiple people including previous owners and this can lead to parts replaced with different size fasteners and hardware. The sizes of the nuts and bolts we give may be different from what you have so be prepared with different size sockets and wrenches. If something is different on your vehicle please let us know and share your info to help other users. If you have any questions or comments or even a different procedure you would like to share please leave it below and please leave your vehicle information.

Begin by removing the front clip, some people claim that you can do this with the front in the service position but do yourself a favor and just remove it completely.
Figure 1

Begin by removing the front clip, some people claim that you can do this with the front in the service position but do yourself a favor and just remove it completely. It only takes a few more minutes and will save you a lot of time and frustration over trying to work around it, especially if this is your first time. Please see our article on radiator replacement for step by step instructions.

Next you will need to remove the inter-cooler; please see our article on intercooler replacement for additional assistance.
Figure 2

Next you will need to remove the inter-cooler; please see our article on intercooler replacement for additional assistance.

Disconnect the wiring connection for the knock sensor on the front left side of the engine (red arrow).
Figure 3

Disconnect the wiring connection for the knock sensor on the front left side of the engine (red arrow).

Use your serpentine belt tool (red arrow) and remove the serpentine belt; please see our article on belt replacement for further instructions.
Figure 4

Use your serpentine belt tool (red arrow) and remove the serpentine belt; please see our article on belt replacement for further instructions.

Use a 16mm wrench and remove the bolt for the belt tensioner bracket on the end of the supercharger (red arrow).
Figure 5

Use a 16mm wrench and remove the bolt for the belt tensioner bracket on the end of the supercharger (red arrow).

Next use a 10mm socket and remove the two bolts holding the dipstick and tube to the engine (red arrows).
Figure 6

Next use a 10mm socket and remove the two bolts holding the dipstick and tube to the engine (red arrows).

Remove the dipstick and tube and make sure to plug the hole to the crankcase (red arrow).
Figure 7

Remove the dipstick and tube and make sure to plug the hole to the crankcase (red arrow). You are going to be removing the water pump and even though you have drained the system there is going to be a fair amount of fluid in the coolant pump when you remove it and you do not want it getting into the crankcase.

Remove the throttle body; please see our article on throttle body replacement for additional assistance.
Figure 8

Remove the throttle body; please see our article on throttle body replacement for additional assistance.

Use a flathead screwdriver and remove the two hose clamps (yellow arrow) and a 10mm socket (red arrow) and remove the air supply tube from the supercharger.
Figure 9

Use a flathead screwdriver and remove the two hose clamps (yellow arrow) and a 10mm socket (red arrow) and remove the air supply tube from the supercharger.

There are two plastic hard hoses attached to the tube that you need to remove (red arrows).
Figure 10

There are two plastic hard hoses attached to the tube that you need to remove (red arrows). Press down on the red circle on the base of the tubes and pull them straight out. These tubes along with the mounts get brittle over the years so take care that you do not damage them when removing.

The previous owner of our project car had broken his and tried to fix it (poorly) with JB Weld and RVT.
Figure 11

The previous owner of our project car had broken his and tried to fix it (poorly) with JB Weld and RVT. Make sure to press down on the red circle and do not attempt to pry it upward with a screwdriver.

Disconnect the wiring for the alternator and remove it; please see our article on alternator removal if you need additional help.
Figure 12

Disconnect the wiring for the alternator and remove it; please see our article on alternator removal if you need additional help.

Use a set of pliers and remove the hose from the front of the water pump (red arrow).
Figure 13

Use a set of pliers and remove the hose from the front of the water pump (red arrow).

Still using the pliers remove the smaller hose on the rear of the pump (yellow arrow) and then use a 13mm socket and or wrench and remove the three bolts (red arrows) holding the supercharger to the water pump.
Figure 14

Still using the pliers remove the smaller hose on the rear of the pump (yellow arrow) and then use a 13mm socket and or wrench and remove the three bolts (red arrows) holding the supercharger to the water pump.

Use a long extension and loosen the two 8mm bolts holding the tube/bracket that the water pump sits in and connects to the block (red arrows) and then pull the pump off the supercharger and block.
Figure 15

Use a long extension and loosen the two 8mm bolts holding the tube/bracket that the water pump sits in and connects to the block (red arrows) and then pull the pump off the supercharger and block. Coolant is going to flow out so be ready to properly catch and dispose of it.

Always replace the O-rings that sit between the block, water pump and tube.
Figure 16

Always replace the O-rings that sit between the block, water pump and tube.

Remove the diverter tube form the supercharger by pushing down on the red circle and lifting it up (red arrow).
Figure 17

Remove the diverter tube form the supercharger by pushing down on the red circle and lifting it up (red arrow).

Use a 13mm socket and remove the four bolts holding the supercharger to the engine (red arrows) the bolts are different lengths so keep track of them.
Figure 18

Use a 13mm socket and remove the four bolts holding the supercharger to the engine (red arrows) the bolts are different lengths so keep track of them.

You can now pull the supercharger and charged air plenum off the engine.
Figure 19

You can now pull the supercharger and charged air plenum off the engine.

With the supercharger off you want to check the block for any damage, dirt or leaks.
Figure 20

With the supercharger off you want to check the block for any damage, dirt or leaks.

You will need to remove the charged air plenum (red arrow) from the old supercharger and transfer it to the new one.
Figure 21

You will need to remove the charged air plenum (red arrow) from the old supercharger and transfer it to the new one. Make sure to replace all of the gaskets and O-rings that you removed during removal. Installation is the reverse of removal and do not forget to refill the coolant.

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Comments and Suggestions:
AJ Comments: Hello, after removal of the tired old supercharger because it is making noise-is it possible to rebuild the unit and re-install? If so, what is recommended to be replaced?
September 29, 2016
  Followup from the Pelican Staff: No, you can send it it to a rebuilder. But no part kits I know of are available. - Nick at Pelican Parts  

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