Air Bypass Valve: Service and Repair

REMOVAL
1. Disconnect vacuum hose.

2. Remove supercharger inlet plenum assembly.

3. Remove actuator-to-supercharger retaining bolts.

4. Remove two self-tapping screws.

5. Rotate actuator to allow rod to pass through keyed slot in bypass lever.


INSTALLATION
1. Install actuator rod in bypass lever, rotate actuator into position. Install 8mm bolt hand tight.

2. Rotate actuator to bring the bypass lever against its stop, then rotate an additional 1.27mm (0.50 inch).
Tighten 8mm bolt to 20-27 Nm (15-20 ft lb) while holding in this position.

3. Check operation of actuator using Vacuum Pump D83L-7059-A or equivalent. The bypass lever should stay against its stop between 0-10 kPa (0-3 in Hg) of applied vacuum. At 27 kPa (8 in Hg) the bypass lever should be fully open (approximately horizontal). If results are not within specification, loosen 8mm bolt and reset. Repeat test procedure.

4. Drill 1/8-inch hole, 10mm deep (0.40 inch) in the inlet elbow using the bottom pre-punched hole in the actuator bracket as a guide.

NOTE:
Use caution so as not to drill through housing. Install a new self-tapping screw. Repeat procedure for top hole in actuator bracket.

5. Connect vacuum hose.

6. Install supercharger inlet plenum assembly.

7. Start engine and check for proper operation and leaks using propane.