GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Turbocharger

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REMOVAL & INSTALLATION



See Figure 1

  1. Disconnect the negative battery cable. Raise the car and safely support it with jackstands.
  2.  
  3. Unfasten the lower fan retaining screw.
  4.  
  5. Disconnect the exhaust pipe.
  6.  
  7. Remove the rear air conditioning support bracket and loosen the remaining bolts.
  8.  
  9. Remove the turbo support bracket-to-engine bolt.
  10.  
  11. Disconnect the oil drain hose at the turbocharger.
  12.  
  13. Carefully lower the vehicle.
  14.  
  15. Disconnect the coolant recovery pipe, then move it to one side.
  16.  
  17. Detach the induction tube.
  18.  
  19. Remove the cooling fan.
  20.  
  21. Disconnect, then remove the oxygen sensor.
  22.  
  23. Unfasten the oil feed pipe at the union. Disconnect the water feed pipe.
  24.  
  25. Disconnect the air intake duct and vacuum hose at the actuator.
  26.  
  27. Unfasten the exhaust manifold retaining nuts and remove the exhaust manifold and turbocharger.
  28.  



Click image to see an enlarged view

Fig. Fig. 1: View of the turbocharger mounting - 1987 2.0L MFI-Turbo shown

To install:
  1. Install the exhaust manifold and turbocharger. Tighten the bolts evenly to 16 ft. lbs. (22 Nm).
  2.  
  3. Install the exhaust manifold retaining nuts.
  4.  
  5. Attach the air intake duct and vacuum hose at the actuator.
  6.  
  7. Connect the oil feed pipe at the union.
  8.  
  9. Attach the oxygen sensor.
  10.  
  11. Install the cooling fan.
  12.  
  13. Connect the induction tube.
  14.  
  15. Position and attach the coolant recovery pipe.
  16.  
  17. Raise and safely support the vehicle.
  18.  
  19. Fasten the rear turbo support bracket bolt to the engine.
  20.  
  21. Install the rear air conditioning support bracket.
  22.  
  23. Connect the oil drain hose at the turbocharger.
  24.  
  25. Fasten the lower fan screw.
  26.  
  27. Attach the exhaust pipe.
  28.  
  29. Connect the negative battery cable, then start the engine and check for intake and/or exhaust leaks.
  30.  

 
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