Water Cooled Turbocharger - Service Replacement
86ford21 Article No. 86-6-12
TURBOCHARGER - 2.3L EFI T/C - WATER COOLED SERVICE REPLACEMENT
FORD 1983-84 THUNDERBIRD, MUSTANG, SVO MUSTANG
LINCOLN-MERCURY 1983-84 COUGAR, CAPRI
Turbocharger failure of any of the above-mentioned vehicles, should be repaired in service with a 1985 water cooled turbocharger assembly (E3ZZ-9G438-D) Thunderbird/Cougar, Mustang/Capri, and (E4ZZ- 9G438-D) SVO only. The following procedure should be performed when installing the new water cooled turbocharger.
NOTE: If TSB 86-3-7 has been completed, only replace heater inlet tube E5ZZ-18B402-A or E5ZZ-18B402-D (SVO only) and new water cooled turbocharger E3ZZ-9G438-D (Thunderbird/Cougar, Mustang/Capri) or E4ZZ-9G438-D (SVO Mustang). If TSB 86- 3-7 has not been performed, proceed with the following:
Figure 7:
Figure 8:
1. Remove the old turbocharger assembly per Car Shop Manual procedures. Figures 7 and 8 show both regular and SVO turbocharger assemblies.
Figure 9:
Figure 10:
Figure 13:
2. Remove the two existing water heater tubes E3ZE- 18698-AB or E4ZE-18698-AA and E3ZE-18674- AC, these tubes will have to be cut as indicated in Figures 9 and 10 to aid tube removal. The -18674- water tube will still have the back portion behind the engine left in place. (See Figure 13)
NOTE: Save all tubing clips and hose clamps for reuse.
NOTE: Step 4 of the New Turbo Water Tubes Installation Procedure could be performed at this time to ease installation.
3. Install the new water cooled turbocharger per the Shop Manual. (Also refer to TSB 85-18-7.)
New Water Heating Tubes Installation
NOTE: 1983 models - remove thermostat housing (E37E-8594-AB) and replace with D8FZ- 8592-A housing and gasket E4ZZ-8255-A (Figure 10).
1. Remove left rear rocker cover bolt - save.
Figure 12:
2. Install E5RY-6K759-A bracket at left rear rocker cover hole (Figure 12) and reinstall bolt removed from Step 1 and torque to 7-11 N-m (5-8 ft.lbs.).
Figure 13:
3. Attach hoses E5RY-8A567-B and E5RY-18472-F to tube E5RY-6B749-B (Figure 13).
4. Install the above (Step 3) to the water pump and engine oil cooler (Figure 13) and torque all clamps to 17-40 N-m (13-30 ft.lbs.).
5. Attach hoses E5ZZ-18472-B and heater core inlet hose (see application chart) to the heater inlet tube E5ZZ-18B402-A (Thunderbird/Cougar, Mustang/ Capri) or E5ZZ-18B402-D (SVO). Then connect hoses to the dash panel and thermostat housing outlet tube (Figure 13) and torque all clamps to 17-40 N-m (13-30 ft.lbs.).
Heater Core Inlet Hose Application
Part Number Application
E5SZ-18472-A A/C T-Bird/Cougar, Mustang/Capri
E4ZZ-18472-B Non A/C Mustang/Capri only
E5ZZ-18472-H A/C SVO Mustang
E5ZZ-18472-E Non A/C SVO Mustang
E5SZ-18D371-B ATC -
Figure 13:
6. Install bracket E3ZZ-18481-B and clip N802623- S2 on tube -18B402- and oil cooler outlet tube E5RY-6B749-B and attach -18481- bracket to rocker cover (Figure 13), at front, with N605890-S2 bolt. Torque bolt to 17-40 N-m (13-30 ft.lbs.).
Figure 12:
7. Install oil cooler hose clip 388557-S100 on the hose E5RY-18472-F and attach to the E5RY- 6K759-A bracket at the left rear or rocker cover with screw E610888-S71 (Figure 12). Torque screw to 7-11 N-m (5-8 ft.lbs.).
Figure 11:
New Turbo Water Tubes Installation
1. Install connector fitting 87527-S100 (Figure 11) to inboard side of turbocharger by open end wrench, torque to 30-45 N-m (23-33 ft.lbs.).
2. Install water outlet tube E5ZZ-8A520-A, to bulk black hose C9PZ-18472-D with hose clamps B7A- 8287-A to the -18B402- tube (Figure 11), torque clamps to 17-40 N-m (13-30 ft.lbs.).
3. Install the opposite end of the water outlet tube E5ZZ-8A520-A to turbo connector fitting 87527- S100 (Figure 11) and torque to 20-28 N-m (15-21 ft.lbs.).
Figure 11:
4. Remove pipe plug (Figure 11) at the cylinder block VIN pad location and discard. Install nipple 390343-S36 and torque to 20-28 N-m (15-21 ft. lbs.).
5. Install elbow fitting 390360-S100 at the turbocharger outboard side and torque to 14-20 N-m (10-15 ft.lbs.), noting the position of the fitting shown in Figure 11.
6. Install turbo water inlet tube (E5ZZ-8A505-A), attach with hose cut from bulk C9PZ-18472-D, between cylinder block and turbocharger (Figure 11). Torque clamps to 1.5-2.5 N-m (12-20 in.lbs.).
a. Fill cooling system.
7. Start engine and check for leaks.
Additional Items For SVO Only
Install high routed heater tubes and water cooled turbocharger on the SVO.
1. Remove the closure tube -6758- and closure hose to the oil separator -6A664- and replace it with (E5ZZ-6758-B) and (E5ZZ-6A664-B) respectively.
2. Remove the front bracket on the inter cooler assembly and replace with E5ZZ-6K784-A bracket.
a. Fill cooling system.
3. Start engine and check for leaks.
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
Thunderbird/Cougar, Mustang/Capri
PART NUMBER PART NAME CLASS
E5RY-18472-F Oil Cooler Outlet Hose C
E5RY-6B749-B Oil Cooler Outlet Tube C
E5ZZ-18B402-A Heater Inlet Tube C
E5RY-8A567-B Hose at Water Pump C
E5ZZ-18472-B Hose at Thermostat C
Housing
E5SZ-18472-A Heater Core Inlet Hose C
(A/C)
E4ZZ-18472-B Heater Core Inlet Hose C
(Non A/C)
E5SZ-18D371-B Heater Core Inlet Hose CG
(ATC)
D8FZ-8592-A (1983) Thermostat AM
Housing
E4ZZ-8255-A (1983) Thermostat A
Housing Gasket
E5RY-6K759-A Oil Cooler Outlet Hose C
Bracket
388557-S100 Oil Cooler Outlet Hose S
clip
E610888-S71 Oil Cooler Outlet Hose S
Clip Screw
E3ZZ-18481-B Bracket at Front Rocker C
Cover
N605890-S2 Bolt - Attaches -18481- S
to Rocker Cover
B7A-8287-A Clamp - Hose at Oil AG
Cooler
N802623-S2 Clip - Retains -18B402- S
and -6B749-
E3ZZ-9G438-D Turbocharger (Water A
Cooled)
E5ZZ-8A505-A Tube - Water Inlet C
E5ZZ-8A520-A Tube - Water Outlet C
390343-S36 1/2" Nipple Fitting S
390360-S100 90~ Elbow at Turbo S
87527-S100 1/2" Fitting at Turbo S
C9PZ-18472-D Bulk Hose BM
SVO Mustang
PART NUMBER PART NAME CLASS
E5RY-18472-F Oil Cooler Outlet Hose C
E5RY-6B749-B Oil Cooler Outlet Tube C
E5ZZ-18B402-D Heater Inlet Tube C
E5RY-8A567-B Hose at Water Pump C
E5ZZ-18472-B Hose at Thermostat C
Housing
E5ZZ-18472-H Heater Core Inlet Hose C
(A/C)
E5ZZ-18472-E Heater Core Inlet Hose C
(Non A/C)
E5RY-6K759-A Oil Cooler Outlet Hose C
Bracket
388557-S100 Oil Cooler Outlet Hose S
clip
E610888-S71 Oil Cooler Outlet Hose S
Clip Screw
E3ZZ-18481-B Bracket at Front Rocker C
Cover
N605890-S2 Bolt - Attaches -18481 - S
to Rocker Cover
E5ZZ-6K784-A Intercooler Front C
Support Bracket
E5ZZ-6758-B PCV Closure Tube C
E5ZZ-6A664-B PCV Closure Hose C
B7A-8287-A Clamps - Hose AG
N802623-S2 Clip - Retains -18B402- S
and -6B749-
E4ZZ-9G438-D Turbocharger (Water A
Cooled)
E5ZZ-8A505-A Tube - Water Inlet C
E5ZZ-8A520-A Tube -Water Outlet C
390343-S36 1/2" Nipple Fitting S
390360-S100 90~ Elbow at Turbo S
87527-S100 1/2" Fitting at Turbo S
C9PZ-18472-D Bulk Hose BM
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: SP9438A86 - Turbocharger and water tube kit.
TIME: 3.0 Hrs.
OPERATION: SP9438A1 - Additional time for thermostat housing on 1983 models.
TIME: 0.3 Hr.
OPERATION: SP9438A2 - Additional time for SVO intercooler bracket.
TIME: 0.1 Hr. DLR. CODING: Basic Part No. 9G438 - Code: 40, 56, or P6