Page 1113 of 2490

The intake elbow di
rects the metered airflow from the electronic throttle outlet (und
erside of the throttle body) into the
intake of the supercharger.
The supercharger by-pass valve assembly is bolted to the intake elbow. The butterfly valve inside the assembly is opened
by a diaphragm actuator operated by vacu um feed from the elbow. At closed or partially open throttle positions, the
butterfly valve opens, allowing th e airflow from the two charge air cooler inlets to be directed back to the supercharger inlet .
This action inhibits the supercharging e ffect and reduces engine torque to non supercharged levels. Progressive opening of
the throttle causes the by-pass valve to gradually close.
On the right-hand side of the elbow a la rge diameter pipe connects to the brake servo. On the left-hand side the smaller
pipe supplies vacuum control for the evaporative emissions system valves.
Emissions from the engine part load breather (bank 1) and pu rged fuel vapor from the EVAP valve are drawn via a common
T piece into the left-hand side of the intake elbow. Re-cir culated exhaust gas enters the intake elbow via the EGR valve
which is mounted directly on the rear of the elbow. Where the EGR system is not used, a blanking plate is fitted.
The fuel system and emission control systems are described more fully in the relevant sections.
Fuel Pressure Regula
tion and
Cruise Control Vacuum Feed
The inlet v
acuum feed fo
r the fuel rail pressure regula tor and the cruise control system is taken from the supercharger
outlet duct. The feed pipe is located below the large charge air cooler coolant filler plug.
Superchar
ger
and associated components
Inta
ke Elbow and Bypass
Page 1114 of 2490
P a
rts List
It
e
m
Par
t
Number
De
scr
iption
1—Inta
k
e Air Temperature Sensor 2
2—Charge Air Cooler - Bank 1
3—Charge Air Cooler - Bank 2
4—Charge Air Cooler - Inlet Duct
5—Supercharger
Outlet D
uct
6—Supercharger
7—Supercharger
Pull
ey
8—Supercharger
Dri
ve Belt
Page 1115 of 2490

is at
tached to the three mounting bosses between the V of the cylinder block
has a fil
led for life inte
rnal lubrication system
is po
sitively aligned with the drive
belt by a doweled mounting bracket
C
harge Air Cooler System
Each cyl
inder bank is fitted with a charge air cooler unit wh
ich supplies pressurized air to the four cylinders via an adaptor
block. The inlet ports to the tw o charge air coolers are connected to the supercharger outlet by an inle t assembly consisting
of rubber ducts and clamp plates . An outlet stub at the rear of each charge air cooler unit provides the connection for the
by-pass valve airflow. The charge air coolers ar e water cooled via a radiator and coolant pump.
Charge Air Cooler Coolant System
Parts List
Each charge air cooler unit is a fin and tube air to liquid heat exchanger. The coolant circuit for the charge air coolers
consists of a pump, ra diator, connecting hoses and a bleed pipe.
It
em
Par
t Number
De
scription
1—Charge air cool
ers
2—Coo
lant hoses
3—Coo
lant pump
4—Radi
ator
5—Ble
ed pipe to main coolant circuit expansion tank
6—Charge air cooler to en
gine
coolant circuit connection
7—Coo
lant top up plug
Supercharger
The supe
rcharger:
Page 1116 of 2490

Intake Air Distribution and Filtering - Air Cleaner
Remo
val and Installation
Remov
a
l
1.
Op
en the engine compartment and fit paintwork protection
sheets.
2. Relea
se the air intake trunking
to gain access to the air
cleaner cover inner rear clip
1. Remove the bolts which secure the trunking to the intake elbow.
2. Release the trunking from the elbow and carefully lift the assembly to gain access to the inner rear
clip.
3. Disc
onnect the air cleaner cover.
R
e
lease the five clips which se
cure the air cleaner cover.
Lift the cover.
4. Re
move the air cleaner cover an
d trunking as an assembly.
1. Release the breather pipe from the camshaft cover.
2. Disconnect the electrical connector from the air flow meter.
Re
move the air cleaner cover and trunking as an
assembly.
5. Lift out the air cleaner element.
6. Disconnect and remove the air cleaner cover from the air flow
meter.
1. Remove the three bolts which secure the air flow
meter to the air cleaner co ver. Remove the blanking
plug.
Carefull y separate the ai
r clea
ner cover from the air flow
meter.
Page 1117 of 2490
I
nstallation
7.
R
emove the air cleaner assembly.
1. Remove the nut which se cures the base of the air
cleaner assembly to the rubber mounting.
2. Release the assembly from the lower rubber mountings.
3. Release the intake section from the assembly and move it clear, into the grommet in the inner wing.
4. Remove the air cleaner assembly.
8. Clean all mating faces of compon ents which are to be refitted.
1. F
it the intake tube/air flow meter/air cleaner cover assembly.
1. Fit a new rubber seal; air in take tube to throttle body.
2
. Fit the intake tube / air
flow meter / air cleaner cover
assembly.
2. R
econnect the air cleaner cover.
1. Fit the five clips which secure the air cleaner cover.
3. Connect the intake tube to the throttle body.
1. Connect the intake tube to the throttle body.
Page 1118 of 2490
2. Fi
t the two bolts which secure the intake tube to the
throttle body.
4. Reconnect the air flow meter multi-plug.
5. Fit a new strap to secures the vacuum pipe to the induction
elbow.
6. Connect the breather pipe to
the A-bank camshaft cover.
1. Fit a new O-ring seal to the breather pipe.
2. Reconnect the breather pipe to the stub pipe.
Page 1119 of 2490
Intake Air Distribution and Filtering - Air Cleaner Element
Re
moval and Installation
Remov
al
Installation
1.
O
pen the engine compartment and fit paintwork protection
sheets.
2. Di
sconnect the air cleaner cover.
1. Release the five clips which secure the air cleaner cover. Lift the cover.
3. R
elease and remove the air cleaner element.
4. Clean the air cleaner cover and body.
1. Installation is th e reverse of the re moval procedure.
Page 1120 of 2490

Intake Air Distribution and Filtering - Charge Air Cooler LH
Remo
val and Installation
Remov
a
l
Installation
1. Disc onne
ct battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).
2. Drain radiator coolant; refer to 26.10.01.
3. Remove air cleaner cover / intake assembly; refer to 19.10.30.
4. Remove throttle body; refer to 19.70.04.
5. Remove exhaust gas re-circulation valve (EGR) if installed;
refer to 17.45.01.
6. Remove throttle intake elbo w; refer to (SC) 19.70.28.
7. Remove supercharger outlet duct; refer to 18.50.16.
8. Remove coolant outlet pipe; refe r to operation (SC) 26.31.08.
9. Remove supercharger drive belt; refer to 18.50.08.
10. Remove supercharger; refer to operation 18.50.15.
11. Detach engine harness retaining clip from rear of charge air
cooler.
12. Di
sconnect hoses from charge air cooler.
Pla
ce absorbent cloth in appropriate position.
Di
sc
onnect hoses.
13 .
CAUTI
ON: Take care to avoi
d dropping any objects or
foreign matter into engine inle t duct with charge air cooler
removed.
Remove charge air cooler from the engine.
1. Remove eight bolts.
Remove charge air cooler.
2
. Discard gasket.
Cle
a
n all mating faces.
1.
Install ch
arge air
cooler to adaptor.
1. Install new gasket.
2. Install charge air cooler.