SUPERCHARGER. ON-VEHICLE INSPECTION 1. INSPECT SUPERCHARGER OIL LEVEL HINT: With the engine cold, check the oil level on the dipstick.

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1 EG45 ONVEHICLE INSPECTION 1. INSPECT OIL LEVEL HINT: With the engine cold, check the oil level on the dipstick. (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 yellowheaded 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 reading 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 to the F mark as follows. (i) Add supercharger oil though the dipstick tube using a vinyl tube and syringe. Supercharger oil: Part No or equivalent (j) Recheck the oil level. HINT: The supercharger could be damaged if it is overfilled or 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 the stator coil between the clutch lead wire terminals. Standard resistance: at 20 C (68 F) If the resistance is not as specified, replace the clutch stator. 3. INSPECT STALL TEST (See page AT88 )

2 EG46 ENGINE 4. INSPECT PRESSURE (a) Using a 3way connector, install SST (turbocharger pressure gauge) to the hose between the intake manifold to the fuel pressure regulator. SST (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 supercharger and supercharger bypass valve.

3 EG47 COMPONENTS FOR REMOVAL AND INSTALLATION

4 EG48 ENGINE

5 EG49 REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE () TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative () terminal cable is disconnected from the battery. 2. DRAIN ENGINE COOLANT 3. REMOVE AIR DUCT 4. REMOVE ENGINE COOLANT RESERVOIR AND BRACKET 5. REMOVE AIR DAMPER CASE 6. REMOVE BLOWER 7. DISCONNECT PS RESERVOIR Remove the 2 bolts and disconnect the PS reservoir. 8. REMOVE RADIATOR (a) Remove the 4 screws and No.2 fan shroud. (b) Stretch the belt and remove the 4 nuts of the fluid coupling. (c) Pull out the fan with fluid coupling.

6 EG50 ENGINE (d) Disconnect the ACV connector. (e) Disconnect the 3 air hoses from the ACV. (f) Remove the No.1 engine under cover. (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. (k) Remove the 2 bolts, 2 supports and radiator. 9. REMOVE THROTTLE BODY (a) Disconnect the accelerator cable.

7 EG51 (b) Disconnect the 4 air cleaner clips. (c) Remove the air cleaner hose. (1) Disconnect the A/C idleup air hose. (2) Disconnect the ventilation tube. (3) Disconnect the air connector vent pipe. (4) Loosen the 2 clamps and remove the air cleaner hose. (d) Disconnect the throttle position sensor and IAC valve connectors. (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 (f) Remove the 4 bolts, throttle body and gasket.

8 EG52 ENGINE 10. REMOVE DRIVE BELT FOR GENERATOR AND PS PUMP Loosen the No.1 idler pulley nut and adjusting bolt, and remove the drive belt. 11. REMOVE PS PUMP (a) Disconnect the 2 PS idleup hoses. (b) Remove the bolt and PS hose clamp. (c) Remove the 5 bolts, pump stay and PS pump with the hoses attached. 12. REMOVE DRIVE BELT FOR Loosen the No.2 idler pulley nut and adjusting bolt, and remove the drive belt.

9 EG REMOVE NO.2 IDLER PULLEY Remove the nut, plate, idler pulley and spacer. 14. REMOVE NO.1 AIR INLET DUCT W/ BYPASS VALVE (a) Disconnect the supercharger bypass valve connector. (b) Disconnect the brake booster hose. (c) Disconnect the A/C idleup air hose. (d) Disconnect the supercharger magnetic clutch connector. (e) Disconnect the supercharger magnetic clutch connector from the No.1 hose support bracket. (f) Remove the 2 bolts and No.1 hose support bracket. (g) Remove the air hoses and 3way.

10 EG54 ENGINE (h) Remove the 2 bolts and 2 nuts holding the supercharger bypass valve to the No.1 air outlet duct. (i) Remove the 5 nuts and No.1 air inlet duct with supercharger bypass valve. (j) Remove the supercharger bypass valve and No.1 air inlet duct gaskets. 15. REMOVE NO.1 IDLEUP PIPE (a) Remove the bolt holding the pipe to the equipment drive housing. (b) Disconnect the air hose and remove the pipe. 16. DISCONNECT NO.1 AIR TUBE Loosen the clamp and disconnect the air tube from the No.1 air outlet duct. 17. REMOVE NO.1 INTAKE AIR CONNECTOR BRACKET Remove the 2 bolts and bracket.

11 EG REMOVE (a) Remove the 2 bolts and 2 nuts holding the supercharger to the equipment drive housing. (b) Remove the 6 nuts holding the supercharger to the No.1 air outlet duct. (c) Separate the supercharger and No.1 air outlet duct and remove the gasket. (d) Remove the supercharger and No.1 air outlet duct.

12 EG56 ENGINE COMPONENTS FOR DISASSEMBLY AND ASSEMBLY

13 EG57 DISASSEMBLY (See Components for Disassembly and Assembly) 1. DRAIN OIL Remove the magnetic plug under the rear cover and drain the oil. 2. REMOVE CLUTCH HUB Using SST, remove the nut, clutch hub and shim. SST REMOVE CLUTCH PULLEY (a) Using SST, remove the ring nut. SST (b) Remove the clutch pulley and shim. 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. 5. REMOVE CLUTCH FLANGE Remove the 5 bolts and clutch flange.

14 EG58 ENGINE 6. REMOVE FRONT COVER Remove the 3 bolts, wire clamp, front cover and gasket. 7. REMOVE REAR COVER Remove the 8 bolts, rear cover and gasket. 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. (c) Remove the 2 bolts and rear plate. 9. IF NECESSARY, REMOVE ELBOW 10. IF NECESSARY, REMOVE UNIONS

15 EG59 COMPONENTS INSPECTION 1. INSPECT HOUSING Check that there is no damage on the inside surface of the housing. 2. INSPECT ROTORS (a) Check that there is no damage on the outside of the rotors. (b) Check that there is no looseness in the rotors and shafts and that the rotors rotate smoothly. 3. INSPECT BEARINGS Check that the bearings are not rough or worn. ASSEMBLY (See Components for Disassembly and Assembly) 1. INSTALL REAR PLATE (a) Remove any packing material and be careful not to drop oil on the contacting surfaces of the rear plate and housing. (b) Apply engine oil to the 4 locations on the upper surface of the rotor. (c) Apply a light coat of adhesive to the outer edge of the groove on the side matching the rear plate. Adhesive: Part No , THREE BOND 1131, LOCTITE 518 or equivalent NOTICE: Do not apply the sealant too liberally or it will overflow the groove in the housing and be squeezed inside the housing. HINT: The groove in the housing is to prevent adhesive being squeezed inside housing. (d) Install the rear plate as soon as the adhesive is applied. (e) Install and torque the 2 bolts. Torque: 4.9 Nm (50 kgfcm, 43 in.lbf)

16 EG60 ENGINE (f) Mount the supercharger in a soft jaw vice. (g) Secure the bolt and install the nut. Install the 2 nuts. Torque: 49 Nm (500 kgfcm, 36 ftlbf) 2. INSTALL REAR COVER Install a new gasket and the rear cover with the 8 bolts. Torque: 5.9 Nm (60 kgfcm, 52 in.ibf) 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 or equivalent Grease capacity: g ( oz.) (c) Install a new gasket, the housing front cover and wire clamp with the 3 bolts. Torque: 5.9 Nm (60 kgfcm, 52 in.lbf) 4. INSTALL CLUTCH FLANGE Install the clutch flange with the 5 bolts. Torque: 5.9 Nm (60 kgfcm, 52 in.lbf)

17 EG61 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 the taper side toward the front. 6. INSTALL CLUTCH PULLEY (a) Install the clutch pulley. (b) Using SST, install the ring nut. SST Torque: 24 Nm (245 kgfcm, 18 ftlbf) 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 Torque: 31 Nm (316 kgfcm, 23 ftlbf) 8. INSPECT AND ADJUST AIR GAP OF MAGNETIC CLUTCH (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 clutch hub.

18 EG62 ENGINE HINT: Take measurements starting from the second time the clutch hub is operated. (d) Measure the other 3 locations using the same method. Use the average value of the 4 locations for the air gap value. Standard air gag: mm ( in.) If the air gap is not within specification, replace the shim. Adjusting shim thickness mm (in.) NOTICE: When measuring, check that the location marks for the pulley and clutch hub are in the correct position. HINT: If the air gap is greater than specification, use a thinner shim. If the air gap is less than specification, use a thicker shim. 9. INSTALL ELBOW (a) Apply a light coat of adhesive to the part of the part of the elbow to be inserted into the housing. Adhesive: Part No , THREE BOND 1131, LOCTITE 518 or equivalent (b) Using pliers and a hammer, tap in the elbow so that it faces the same way as in the illustration.

19 EG INSTALL UNIONS Using a hammer, tap the union into place with a block of wood, etc., placed between the union and the hammer. 11. FILL WITH OIL (a) Clean and install the magnetic plug with a new gasket. (b) Fill the supercharger with new oil. Supercharger oil: Part No or equivalent Oil capacity: 130 cm 3 (7.9 cu in.) INSTALLATION (See Components for Removal and Installation) 1. INSTALL (a) Place the No.1 air outlet duct in position as shown. (b) Assemble the No.1 air outlet duct and supercharger with a new gasket and 6 nuts. Torque: 9.3 Nm (95 kgfcm, 82 in.lbf) (c) Install the supercharger to the equipment drive housing with the 2 bolts and 2 nuts. Torque: 37 Nm (375 kgfcm, 27 ftlbf)

20 EG64 ENGINE 2. INSTALL NO.1 INTAKE AIR CONNECTOR BRACKET Install the bracket with the 2 bolts. Torque: 18 Nm (185 kgfcm, 13 ftlbf) 3. CONNECT NO.1 AIR TUBE Connect the air tube to the No.1 air outlet duct with the clamp. 4. INSTALL NO.1 IDLEUP PIPE (a) Connect the air hose to the supercharger. (b) Install the pipe to the equipment drive housing with the bolt. Torque: 7.5 Nm (80 kgfcm, 69 in.lbf) 5. INSTALL NO.1 AIR INLET DUCT W/ 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 bypass valve with the 5 nuts. Torque: 5.4 Nm (55 kgfcm, 48 in.lbf) (c) Install the supercharger bypass valve with the 2 bolts and 2 nuts. Torque: 5.4 Nm (55 kgfcm, 48 in.ibf)

21 EG65 (d) Install the air hoses and 3way. (e) Install the No. 1 hose support bracket with the 2 bolts. Torque: 7.5 Nm (80 kgfcm, 69 in.lbf) (f) Connect the supercharger magnetic clutch connector. (g) Connect the supercharger magnetic clutch connector to the No.1 hose support bracket. (h) Connect the brake booster hose. (i) Connect the A/C idleup air hose. (j) Connect the supercharger bypass valve connector. 6. INSTALL NO.2 IDLER PULLEY Temporarily install the spacer, idler pulley and plate with the nut.

22 EG66 ENGINE 7. INSTALL AND ADJUST DRIVE BELT FOR Install and adjust the drive belt with the adjusting bolt and No.2 idler pulley nut. Drive belt tension: New belt 170 ± 10 lbf Used belt 125 ± 10 lbf 8. INSTALL PS PUMP (a) Install the PS pump and stay with the 5 bolts. Torque: Long bolt 48 Nm (490 kgfcm, 35 ftlbf) Short bolt 36 Nm (370 kgfcm, 27 ftibf) (b) Install the PS hose clamp with the bolt. Torque: 11.5 Nm (120 kgfcm, 9 ftlbf) (c) Connect the 2 PS idleup hoses. 9. INSTALL AND ADJUST DRIVE BELT FOR GENERATOR AND PS PUMP Install and adjust the drive belt with the adjusting bolt and No.1 idler pulley nut. Drive belt tension: New belt 170 ± 10 lbf Used belt 125 ± 10 lbf

23 EG INSTALL THROTTLE BODY (a) Install a new gasket and throttle body with the 4 bolts. Torque: 18 Nm (185 kgfcm, 13 ftlbf) (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 (c) Connect the throttle position sensor and IAC valve connectors. (d) Install the air cleaner hose. (1) Install the air cleaner hose with the 2 clamps. (2) Connect the A/C idleup air hose. (3) Connect the ventilation tube. (4) Connect the air connector vent pipe. (e) Install the 4 air cleaner clips.

24 EG68 ENGINE (f) Connect the accelerator cable. 11. INSTALL RADIATOR (a) Place the radiator in position, and install the 2 supports with the 2 bolts. Torque: 18 Nm (185 kgfcm, 13 ftlbf) (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.

25 EG69 (i) Temporarily install the fluid coupling w/ cooling fan with the 4 nuts. (j) While pressing down on the generator drive belt, torque the 4 nuts for the coupling. Torque: 13.5 Nm (135 kgfcm, 10 ftlbf) (k) Install the No.2 fan shroud with the 4 bolts. 12. INSTALL PS RESERVOIR Install the PS reservoir with the 2 bolts. Torque: 12.5 Nm (130 kgfcm, 9 ftlbf) 13. INSTALL BLOWER 14. INSTALL AIR DAMPER CASE 15. INSTALL ENGINE COOLANT RESERVOIR AND BRACKET 16. INSTALL AIR DUCT 17. FILL WITH ENGINE COOLANT 18. CONNECT NEGATIVE () TERMINAL CABLE TO BATTERY 19. START ENGINE AND CHECK FOR COOLANT BATTERY