Introduction

The Kenne Bell 2.2L twin-screw supercharger is one of the most effective bolt-on upgrades for the GM 3800 Series II and Series III V6 engine. This positive-displacement blower delivers instant throttle response and a broad torque curve, transforming a daily driver into a street predator. This expanded guide provides a detailed, step-by-step installation process, covering preparation, disassembly, mounting, plumbing, and initial testing. Whether you are a seasoned enthusiast or a first-time supercharger installer, these instructions will help you complete the job safely and correctly.

Tools and Materials Needed

Having the correct tools and new components on hand before you start prevents delays and ensures a quality installation. The Kenne Bell 2.2L kit typically includes the supercharger assembly, intake manifold, throttle body adapter, intercooler, belt, and all necessary hardware. You will also need the following:

  • Socket set – 1/4" and 3/8" drive, metric (10mm, 13mm, 15mm, 18mm).
  • Wrenches – combination open-end/box-end, metric sizes.
  • Torque wrench – 3/8" drive, 15–75 ft-lb range.
  • Ratchet with extensions and universal joint.
  • Pry bar or flathead screwdriver for stuck hoses.
  • Gasket scraper – plastic to avoid scoring surfaces.
  • Thread lock compound (medium strength, blue).
  • RTV silicone gasket maker – high-temperature, oil-resistant.
  • Supercharger kit parts – verify you have the supercharger, intercooler, bypass valve, belt, gaskets, fuel injectors (if upgrading), and hardware.
  • Fuel injectors – 42 lb/hr or 60 lb/hr high-impedance injectors (recommended for boosted 3800).
  • Coolant – Dex-Cool or compatible 50/50 mix.
  • Engine oil – 5W-30 synthetic.
  • Shop towels – lint-free.
  • Safety glasses and gloves.
  • Jack and jack stands or ramps if you need to access under the vehicle.

Optional but helpful: a vacuum/pressure gauge, fuel pressure gauge, and a scan tool to monitor engine data during initial startup.

Preparation

Workspace Preparation

Choose a clean, well-ventilated area with ample light. If working in a garage, ensure the door is open to exhaust fumes. Place a fire extinguisher within reach. Cover the fenders with protective blankets to prevent scratches.

Vehicle Preparation

Park the vehicle on a level surface and engage the parking brake. Disconnect the negative battery terminal – this prevents accidental short circuits and resets the ECU, which is beneficial for a new tune. Allow the engine to cool completely; the upper intake manifold and engine block can be hot enough to cause burns. If you need to drain coolant, wait until the radiator cap is cool to the touch.

Drain Coolant and Oil

Place a drain pan under the radiator petcock and open it. Remove the coolant reservoir cap to speed draining. While the coolant drains, remove the oil filler cap and drain the engine oil. Reinstall the oil drain plug with a new crush washer and torque to 20 ft-lb. Refilling oil will happen later. Having the engine dry during installation prevents contamination.

Removing Stock Components

Carefully remove all parts that will be replaced or interfered with by the supercharger. Work slowly and label connectors and hoses with tape to ease reassembly.

  1. Remove the air intake system. Unbolt the mass air flow sensor, disconnect the intake tube from the throttle body and air box. Remove the entire assembly.
  2. Disconnect the throttle body. Unplug the TPS and IAC connectors. Remove the throttle cable and bracket. Unbolt the throttle body (four 10mm bolts) and set aside. The gasket is reusable if intact.
  3. Remove the upper intake manifold. Label and disconnect all vacuum lines, the brake booster line, and EVAP purge line. Unbolt the upper intake manifold (six 8mm bolts). Lift it off carefully – the lower intake manifold gaskets may stick. Clean the lower intake surface with a gasket scraper.
  4. Remove fuel rails and injectors. Depressurize the fuel system by pulling the fuel pump fuse and cranking the engine for a few seconds. Disconnect fuel lines (use a Schrader valve cap to release pressure). Unbolt the fuel rail (two 10mm bolts) and carefully lift, pulling injectors from the lower intake. Remove the lower intake manifold (six 8mm bolts). Clean the cylinder head surfaces.
  5. Remove accessories if needed. The Kenne Bell kit often requires relocating the alternator or power steering reservoir. Follow the kit instructions; typically the alternator moves to a lower bracket (provided). Unbolt the alternator, remove belt, and reinstall with the supplied bracket.

Tip: Soak stubborn exhaust manifold bolts with penetrating oil before removal. Use a box-end wrench on the rear AC compressor bracket bolts.

Installing the Kenne Bell Supercharger

With the engine bay clear, you can now install the supercharger assembly. The 2.2L unit is heavy – have a helper support it during placement.

Install the Intercooler Brick (if equipped)

Most Kenne Bell 2.2L kits for the 3800 include an air-to-air intercooler core that bolts between the supercharger and the lower intake. Place the intercooler gasket on the lower intake, then position the intercooler. Secure with the provided bolts (torque to 10 ft-lb in a crisscross pattern).

Mount the Supercharger

  1. Apply a thin bead of RTV to the gasket surfaces. Place the supercharger gasket on the intercooler or lower intake (depending on kit configuration).
  2. Lower the supercharger assembly onto the mounting studs. Align the snout with the accessory drive belt path. The Kenne Bell unit uses a special pulley alignment; check that the pulley is straight with the crank pulley and tensioner.
  3. Install the mounting bolts (usually four large hex-head bolts). Tighten in a diagonal sequence to the manufacturer’s specified torque – typically 35 ft-lb. Use thread lock on the bolts.
  4. Install the bypass valve (supplied). The diaphragm should be oriented according to the manual. Connect vacuum line to the manifold vacuum source.
  5. Reinstall the throttle body onto the supercharger snout using the provided adapter plate and gasket. Torque bolts to 10 ft-lb. Reconnect the throttle cable and sensor connectors.

Install the Belt and Accessories

Route the supercharger belt as per the included diagram. The Kenne Bell kit often uses a longer belt that also drives the alternator. Tension by moving the alternator outward. Use a belt tension gauge (spec: 100–120 lbs for new belt). Secure the alternator bracket bolts. Reinstall any other moved accessories (like the power steering pump).

Connecting Fuel and Cooling Lines

Proper fuel delivery and cooling are critical for boosted engines.

Fuel System

  1. If you are upgrading injectors (strongly recommended for anything above 7 psi), install the new high-impedance injectors into the fuel rail. Lubricate O-rings with clean oil. Seat them fully.
  2. Attach the fuel rail to the lower intake (or supercharger lower manifold). Torque bolts to 15 ft-lb. Connect the fuel pressure regulator (if external) with the vacuum reference line to intake manifold boost pressure.
  3. Connect the fuel supply line – use a quick-connect tool to ensure a firm click. For return-style systems, attach the return line. Check that there are no kinks.
  4. Turn the ignition key to "ON" (engine off) to pressurize the fuel system. Inspect for leaks at all connections. Repair as needed.

Coolant Lines

The Kenne Bell 2.2L kit may include a water-to-air intercooler system (if not using the air-to-air brick). For water-to-air, you will need to mount a heat exchanger, pump, and reservoir. Route the hoses away from the exhaust. Fill the system with a 50/50 coolant mix. Bleed air by running the pump (if electric) with the reservoir cap open.

If your kit is air-to-air, the intercooler bricks do not use coolant – only engine coolant lines are reconnected. Hook up the heater core hoses and radiator hoses. Ensure no leaks at the water pump or intake.

Finalizing the Installation

Reattach Remaining Components

  • Reinstall the air intake system – attach the intake tube to the supercharger inlet. Some kits use a larger MAF housing; follow the instructions for sensor placement.
  • Connect all vacuum lines, PCV hoses, and electrical connectors. Double-check the MAP sensor, IAT, and TPS.
  • Reconnect the negative battery terminal.
  • Refill engine oil (5W-30 synthetic, 5–6 quarts).
  • Refill coolant through the radiator and reservoir. Use a spill-free funnel to burp the system.

Belt Tension and Alignment Check

Rotate the crank pulley by hand (using a socket on the harmonic balancer bolt) to ensure the belt tracks straight. The supercharger rotor should spin freely without binding. If it feels tight, loosen the belt tensioner and adjust.

Testing the Installation

Initial Start-Up

Before cranking, prime the fuel system by turning the key to RUN for three seconds, then OFF, repeat three times. This fills the fuel rails. Start the engine and let it idle. Expect a slightly high idle (up to 1000 RPM) as the ECU adapts. Listen for any metallic rubbing, belt squeal, or vacuum leaks. Check the oil pressure gauge.

Leak Inspection

With the engine running, inspect all fuel line connections, coolant hoses, and vacuum lines. Use a soapy water solution on the supercharger gaskets to detect air leaks (bubbles). For boost leaks, you can use a smoke machine or a homemade boost leak tester (PVC cap with a Schrader valve and a coupler). Pressurize the intake to 10 psi and listen for hissing.

Test Drive

Once the engine reaches operating temperature and no leaks are present, take the car for a short test drive. Avoid full throttle until the engine has completed several heat cycles. Gradually increase boost to 5–7 psi to seat the piston rings. Monitor the AFR using a wideband gauge (target 12.0–12.5:1 under boost). If your vehicle has not been tuned, keep boost low and limit RPM to 4,000 until you can schedule a professional dyno tune.

Tuning Requirements

The Kenne Bell 2.2L supercharger will push the stock fuel system beyond its limits. A custom tune via a flash tool (such as HP Tuners or a mail-order tune from a reputable shop like ZZ Performance or Intense Racing) is mandatory. Without proper tuning, you risk engine damage from detonation. Adjust the fuel table, spark advance, and boost levels to match your injectors and octane. For further reading, join the 3800 Pro forums for community support.

Conclusion

Installing a Kenne Bell 2.2L supercharger on a 3800 V6 is a rewarding project that can yield 100+ horsepower gains when combined with proper supporting mods and a tune. By following this expanded step-by-step guide, you will avoid common pitfalls such as leaky gaskets, incorrect belt routing, and fuel starvation. Remember to verify every torque spec, take your time during removal, and always prioritize safety. Once the installation is complete and the vehicle is tuned, you will enjoy a responsive, supercharged 3800 that delivers neck-snapping torque every time you press the throttle. For the official Kenne Bell instruction manual, visit KenneBell.com. Happy boosting!