Subaru ff-1/1300/1400/1600/1800/Brat 1970-1984 Repair Guide

Turbocharger

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REMOVAL & INSTALLATION




WARNING
Do not allow dirt to enter either intake or outlet openings, or the unit may be destroyed at start up.

  1. Loosen clamps and remove the air intake duct (leading from the air cleaner to the intake of the flowmeter).
  2.  



Click image to see an enlarged view

Fig. Fig. 1 Exploded view of the turbocharger and associated components

  1. Loosen the clamps at either end and at the vacuum hose connector, and remove flowmeter boot (connecting the flowmeter to the turbocharger intake).
  2.  
  3. Remove the mounting bolts from the turbocharger exhaust outlet. Separate the pipe from the turbocharger.
  4.  
  5. Back off the clamp and for the turbocharger drain hose.
  6.  
  7. Disconnect the oil supply line from the top of the turbocharger.
  8.  
  9. Then, loosen and remove the three turbocharger mounting bolts and remove the turbocharger and gasket from the exhaust manifold, disconnecting the drain hose at the same time.
  10.  

To install:

  1. Install the turbocharger using a new gasket.
  2.  
  3. Connect the oil supply line and tighten the bolts to 8-13 ft. lbs. (10-17 Nm).
  4.  
  5. Install the clamp for the turbocharger drain hose.
  6.  
  7. Install the turbocharger exhaust outlet and fasten the mounting bolts to 31-38 ft. lbs. (42-51 Nm).
  8.  
  9. Install the flowmeter boot and fasten the clamps at the vacuum hose connector.
  10.  
  11. Install the air intake duct and fasten the clamps.
  12.  

TROUBLESHOOTING



The turbocharger cannot be repaired. The entire unit must be replaced if there is a major mechanical defect. However, you can determine whether or not the seals or bearing are defective, meaning that the unit must be replaced.

Exhaust Side Oil Leak

Inspect the turbocharger exhaust outlet for excessive deposits of hard carbon. These deposits, not to be confused with light layer of normal exhaust soot, indicate oil is leaking past the bearing seal on the exhaust side and forming the carbon due to exhaust heat. Replace the unit.

Intake Side Oil Leak/Bad Bearing

Inspect the intake of the turbocharger for heavy accumulations of fresh oil. There will normally be some oil here because of the PCV system. If you suspect a leak, check axial (in and out) or radial (side-to-side) play in the turbocharger bearing. Use a dial indicator. The limit for axial play is 0.0035 in. (0.88mm) while the limit for radial play is 0.0067 in. (0.170mm)

Checking the Waste Gate

If the engine exhibits severe detonation, the waste gate may be inoperative. Disconnect the waste gate control hose at the waste gate and seal it. Then apply 7-9 psi (48-62 kPa). This must be precisely controlled or the waste gate diaphragm may be damaged. Watch the waste gate to see if it operates. If the waste gate does not move, replace the diaphragm. If this does not cure the malfunction, replace the unit.

If the pressure hose to the waste gate is cracked, replace it.

 
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