Turbocharger - Watercooled Turbo Kit, Installation
NUMBER 02-39-85APPLICABILITY: ALL 1983 AND 1984 TURBO VEHICLES DATE: 01-08-85
SUBJECT: TURBO REPLACEMENT
Be advised that a Water Cooled Turbo Kit (P/N 144 10AA 000) is available for installation on 1983 and 1984 Turbo vehicles, should replacement of the original Turbo Unit be necessary.
To properly install a Water Cooled Turbo Kit onto any vehicle originally equipped with an Air Cooled Turbo, follow the instructions below:
NOTE: THE USE OF AIR TOOLS DURING TURBO REPLACEMENT MAY CAUSE DAMAGE TO THE TURBO UNIT OR THE FRONT EXHAUST PIPE, AND IS NOT PART OF THE RECOMMENDED SERVICING PROCEDURE.
1. Allow the engine to cool sufficiently.
2. Disconnect the battery.
3. Remove the jack and spare tire, disconnect the air temperature sensor from the spare tire support and swing the support up, out of the way.
Figure 1 - Turbo Replacement:
4. Remove the washer bottle, disconnecting the two pole electrical connector only, and lay it aside.
5. Remove and save the air intake duct for later reinstallation.
6. Remove the air flow-meter duct from between the air flow-meter and the Turbo unit and save it for later reinstallation (See Figure 1).
7. Remove the original upper heat shield and discard it, saving the bolts for later reinstallation (A 13 mm wrench may be needed as a back-up on some bolts).
NOTE: SATURATE ALL MOUNTING STUDS AND FITTINGS, WITH CRC 5-56 OR THE EQUIVALENT, AND LET SOAK BEFORE ATTEMPTING TO REMOVE THE TURBO UNIT.
8. Disconnect the oil delivery tube from the Turbo unit.
9. Unbolt the two upper mounting brackets on the oil delivery tube.
10. Disconnect the oil return hose at the bottom of the Turbo-Unit.
11. Using a 6-point 14 mm socket, remove the four nuts securing the exhaust pipe to the Turbo Unit, saving the 14 mm nuts and the L-shaped bracket on the rear of the Turbo-unit for later reinstallation.
12. Remove and save the radiator cap.
13. Raise the vehicle.
14. Remove the skid plate.
15. Unbolt the lower bracket on the oil delivery tube.
16. Disconnect the lower banjo fitting of the oil delivery tube from the oil pump and lay it aside being careful not to bend it.
17. Using a 10 mm wrench, remove the two bolts from the heat shield on the catalytic converter.
18. Using a 14 mm wrench, remove the two mounting bolts on the catalytic converter and push it back out of the way.
19. Remove and discard the drain plug located in the right cylinder head, and drain the coolant into a clean container to be saved.
FIGURE 2 - Coolant Feed Tube:
20. Install the coolant feed tube, with the banjo fitting into the drain plug hole, with two (2) copper gaskets and banjo fitting bolt (See Figure 2).
21. Lower the vehicle.
22. Using compressed air, blow out the oil line banjo fittings and the
oil feed line from the oil pump end of the oil feed tube.
23. By undoing the three 14 mm mounting nuts, remove the original Turbo Unit, the lower exhaust gasket, lower heat shield and discard them. Save the 14 mm mounting nuts and the 10 mm bolt securing the lower exhaust gasket to the lower heat shield for later reinstallation.
24. Remove the oil return tube, blower inlet duct, and the oil feed tube mounting bracket from the original Turbo unit and install them with new gaskets onto the new water-cooled Turbo-unit for later installation.
25. To prevent damage to the new Water-Cooled Turbo Unit, plug all openings before installation.
26. Secure the rear section of the coolant feed tube to the rear of the engine block using the bolt supplied.
FIGURE 3 - ELECTRIC THERMO SENSOR:
27. Disconnect and remove the single pole electric thermo-sensor located under the thermostat housing (See Figure 3).
FIGURE 4 - HEATER HOSE ASSEMBLY:
28. Assemble the two short heater hoses onto the "T" fitting with two
(2) hose clamps, and install the thermo-sensor from the thermostat housing with a new "O"-Ring, into the "T" fitting (See Figure 4).
29. Connect the wiring harness to the thermo-sensor and secure the ground wire, using several washers as shims, to the "T" fitting with a 10 mm bolt.
30. Saving the two original hose clamps, disconnect and discard the upper heater hose from between the A/T dipstick tube and the engine.
31. With the two original hose clamps used on the heater hose, install the unit previously assembled in steps #28 and #29 with the longer hose toward the firewall pointing down, being careful not to leave any kinks in the hose.
Figure 5A - Ground Eye Connector to Bolt:
Figure 5B - Connect Male & Female Connectors:
32. Route the wire harness from the thermo-sensor toward the thermostat housing and ground the eye connector of the wiring harness to the 10 mm bolt located at the rear of the intake manifold (See Figure 5A). Connect the male connector of the wire harness to the female connector originally connected to the single pole thermo-sensor removed from the thermostat housing (See Figure 5B).
Figure 6 - Thermostat Housing:
33. After loosening the spark plug wire bracket on the thermostat housing to gain access, install the larger banjo fitting with two (2) copper gaskets and a bolt into the thermostat housing (See Figure 6).
Figure 7 - Thermostat Housing:
34. Then retighten the spark plug bracket.
35. Connect the long coolant hose with a hose clamp between the banjo fitting at the thermostat housing and route the hose around the thermostat housing towards the Turbo-Unit location (See Figure 7).
NOTE: WHEN INSTALLING A NEW WATER-COOLED TURBO-UNIT AN ANTI-SEIZE COMPOUND MUST BE USED ON THE THREADED PORTIONS OF ALL FASTENERS.
Figure 8 - Water-cooled Turbo Unit:
36. With a new lower gasket and lower heat shield install the water-cooled Turbo unit, using the three original 14 mm nuts, with the insulated lower water hose and clamps (See Figure 8).
37. Place the exhaust pipe with a new gasket onto the rear of the Turbo-unit.
38. Place the L-shaped bracket, removed in step #9, onto the rear of the Turbo-unit.
39. Using the four original 14 mm nuts secure the exhaust pipe to the Turbo-unit.
40. Connect the upper water hose onto the Turbo-Unit using a hose clamp.
41. Connect the lower hose to the coolant feed tube leading from the right side of the engine installed in step #20.
42. Reconnect the oil return hose to the bottom of the Turbo-Unit.
43. Install the new upper heat shield.
44. Reinstall the oil delivery tube onto the oil inlet of the Turbo unit and connect its two upper mounting brackets.
45. Reinstall the air inlet duct, air flow meter duct, and the washer bottle.
46. Raise the vehicle.
47. Reconnect the oil delivery tube onto the oil pump and reconnect its lower mounting bracket.
48. Reinstall the skid plate.
49. Reinstall the two 14 mm mounting bolts onto the catalytic converter and the two 10 mm bolts onto the heat shield.
50. Lower the vehicle.
51. Reconnect the battery.
52. Refill the cooling system to its' specified capacity.
53. Disconnect the coil wire and crank the engine until the engine receives oil pressure.
54. Reconnect the coil wire and start the engine.
55. Run the vehicle to normal operating temperature and check for any oil or coolant leaks.
56. Check the operation of the vehicles instrumentation and reset the clock.
57. Install the spare tire and the jack.
THIS OPERATION IS WARRANTABLE UNDER OPERATION #127-011 AND IS GIVEN A TIME ALLOWANCE OF 1.8 HRS.