Hatchback 4WD F4-1781cc 1.8L (1983)
Turbocharger: Technical Service Bulletins
Turbocharger - Watercooled Turbo Kit, Installation
NUMBER 02-39-85
APPLICABILITY: 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.
