I have been noticing a bit of a rattle and I think it is coming from the SC coupling. With the belt off, there is about 1/16" of play, measured at the rim of the pulley. Is this enough to cause the noise?

Absolutely. Change it fairly soon. Sometime this summer.

That'* what I was afraid of. And while I am at it, I will pull the intake manifold because it'* leaking oil pretty badly on the ends. And after that the oil pan needs to come down cuz that gasket is sticking out and leaking. Does it ever end?

Will, I think you had some pages detailing the SC job, with a list of parts. I need to find that. Should I worry about the bearings in the SC?

Are there any watch outs with the intake manifold, or is that straightforward?

Just do a search on 'rebuild' in the forced induction forum. Mine isn't the only detailed job. If your SC isn't leaking oil, or making any other noise and feels like it spins freely, just do the coupler and oil.

Pulling the lower intake won't take much longer after the SC is off. You need to replace the 2 seals at the ends of the block just beneath it, but at that point, you'll have to replace the gaskets between the lower intake and heads, too. You may just want to by the 'head' kit, and set the 2 head gaskets aside. It should come with everything you need. Go AC Delco on that.

This isn't a tough job at all. Just buy a $15 service manual before starting, but make sure it has the SC pull in it. Tearing the charger apart, you'll need our posts as reference.

This might come in particularly handy. It'* an M90, but almost identical in procedure:
http://www.bonnevilleclub.com/forum/...hlight=rebuild

The photo gallery on my website has tons of teardown pics. Click on my sig pic, and surf around. At the bottom of my links list, above my photos, you'll see a link to the gallery.

Thanks Will, I have the complete GM manual set for the car.
You haven't commented on my Bosch plugs, see the pinging topic on the 1992 forum.