Turbocharger - Replacement Procedure
85mitsubishi02SUBJECT:
CORDIA/TREDIA TURBOCHARGER REPLACEMENT
NO. STB-85-09-007
DATE December 1985
MODEL 1983-84 Cordia/Tredia
PURPOSE This bulletin contains the procedure for replacing the non-watercooled turbocharger in the 1983-84 Cordia and Tredia with a watercooled turbo similar to that used in 1985 and later models.
PARTS REQUIRED Parts required for the conversion are:
1 - Watercooled Turbo Kit MD997209
1 - Cartridge Assembly MD613504
LABOR OPERATION CODE AND TIME ALLOWANCE
Labor Operation Code: 09 46 01 90
Time Allawance: 4.0 hrs.
PROCEDURE
1. Position the car on a hoist.
2. Drain the engine coolant.
3. Disconnect the accelerator cable and, if so equipped, the cruise control cable.
4. Disconnect the water temperature sensor connector and the oxygen sensor connector.
5. Remove the following
a. Air intake pipe
b. Air intake hose
c. Secondary air pipe
d. Three heat shields
6. Disconnect the wastegate actuator vacuum tube, and remove the wastegate actuator.
7. Disconnect and remove the turbo oil inlet pipe
8. Raise the car on the hoist.
9. Disconnect the catalytic converter clamp bolt and flange nut.
10. Lower the car to the floor.
11. Remove the catalytic converter.
12. Disconnect the oil drain pipe from the turbo and the engine oil pan. Inspect the pipe for restrictions; replace if restricted or clogged.
13. Remove 2 bolts and 2 nuts to disconnect the turbine housing from the exhaust manifold, and lift the turbo assembly carefully out of the car.
14. Clamp the compressor housing in a soft-jawed vise, remove the clamping ring, and separate the turbine housing from the cartridge assembly.
15. With snapring pliers, remove the snapring securing the compressor housing to the cartridge, and then separate the two.
16. Inspect the turbine housing and compressor housing for damage caused by the turbine wheels. If damage is evident replace the component.
17. Oil the O-ring on the new cartridge MD613504 and assemble it to the compressor housing, being sure to index the notch in the cartridge with the locating dowel in the housing.
18. Reinstall the snapring, beveled side up.
19. Assemble the turbine housing to the cartridge. Note the locating pin which must fit into the hole in the turbine housing. Reinstall the clamp and tighten the clamp bolt to 10-11 N-m (85-95 in.lbs).
20. Remove the upper heater hose - the one connected to the thermostat housing.
21. Remove the water pipe from the engine.
22. Lubricate the O-ring from the kit and assemble it to the water pipe.
23. Thread the flare nut on the water outlet pipe onto the water pipe, but leave it loose so the pipe can swing from side to side.
24. Install the water pipe on the engine.
25. Attach the water inlet pipe to the turbo with the new eyebolt and copper washers from the kit.
26. Connect the water hose, clips, and tee to the water inlet pipe.
27. Install the two curved rubber hoses where the upper heater hose used to be. Slide four clamps MA609047 over the hoses, insert the tee, and tighten the clamp screws.
28. Using the new gasket from the kit, position the turbo assembly on the exhaust manifold, and install the attaching fasteners loosely.
29. Install the eyebolts and copper washers to connect the water inlet and outlet pipes to the turbo cartridge. Torque the eyebolts to 28-33 N-m (21-25 ft.lbs.).
30. Pour some clean engine oil into the turbine oil inlet to provide initial lubrication of the bearings when the engine is started.
31. Install the new oil inlet pipe using previouslyremoved eyebolts and new copper washers from the kit. Torque the eyebolts to 28-33 N-m (21- 25 ft.lbs.).
32. Raise the car on the hoist and reinstall the oil drain pipe using new gaskets and packings MF550031 from the kit. Torque the attaching bolts to 8-10 N-m (72-84 in.lbs.).
33. Tighten the water inlet pipe flare nut to 34-45 N-m (25-33 ft.lbs.).
34. Lower the car, and tighten the turbo housing attaching fasteners to 49-68 N-m (37-50 ft.lbs.).
35. Reinstall the catalytic converter, using a new gasket from the kit. The tab on the gasket goes. Tighten the flange nuts to 8-9 N-m (6-7 ft.lbs.).
36. Attach the oil pipe to the bracket on the water pipe, using the screw and washer assembly from the kit.
FIGURE 1:
37. Install heat shield "A" and supporting bracket, both included in the kit, to the exhaust manifold stud near the oil inlet pipe as shown in Fig. 1.
38. Reinstall and reconnect all parts removed and disconnected previously. Torque all fasteners to torques recommended in the Service Manual.
39. Refill the cooling system. Start the engine and allow it to idle. Check for leaks and proper operation.