TURBO CHARGER SERVICE KIT (NEW PARTS AND PROCEDURE)

1984-86 SUNBIRD MODELS WITH 1.8L

This bulletin replaces bulletin 86-6(GAS)-66 issued 7/89. Please discard bulletin 86-6-66 issued 7/89 as there is already a bulletin with that number. The new number for this bulletin is 86-6-86.

A new water-cooled turbocharger center housing has been made available to service for 1984-86 Overhead Cam (OHC) turbos. The water cooling feature is similar to (but not interchangeable with) that in the 1987/89 OHC models. This service unit feature will reduce bearing hot soak temperature in the 1984-86 production units.

To install this service unit, the following parts should be ordered from GMSPO.

1. Coolant Pipe Kit, P/N 10106082 (includes hardware and installation instructions)

2. Thermostat Housing Service Kit, P/N 10116245 (includes thick flange housing assembly, gasket, longer attaching bolts, and instruction sheet)

3. Turbocharger (Center-Cooled Housing) Turbo Assembly, P/N 10106086

Parts are expected to be available on July 31, 1989. Until then normal part orders will not be accepted by GMSPO. Only verifiable emergency VIP orders will be accepted. SPO will make every effort to obtain parts. All parts will be placed on 400 control to waive VIP surcharges. However, the part will be shipped premium transportation at dealer's expense. All other order types will be canceled as incorrectly ordered while the 400 control is in place.

The recommended procedure to install this service package is as follows:

1. Disconnect battery.

2. Drain Coolant.

3. Remove thermostat housing, and clean cylinder head sealing face for new gasketed thermostat housing. Transfer sensors and thermostat to new housing, and install on engine.

4. Remove turbocharger assembly, as defined in Section 6J-5. To ease removal, disconnect turbo oil drain at engine block, remove upper radiator hose and oil dipstick assembly.

5. Transfer turbo exhaust outlet elbow and turbo inlet induction hose to new turbo unit.

6. Install coolant feed line (loose) , coolant return line, and clamp, as per supplied instructions to the NEW turbocharger center housing assembly.

7. Inspect the oil feed and return lines for contamination. If contamination is suspect, then replace lines.

8. Install oil feed and return lines to NEW turbocharger assembly.

9. Install new turbocharger assembly to engine, as defined in Section 6J-5.

10. Install coolant kit heater hose "T" and turbocharger coolant return hose, as per kit instructions.

11. Finish tightening coolant feed line at turbocharger center housing and at thermostat housing.

12. Check all installed coolant line hose clamps for tightness.

13. Refill cooling system.

14. Reconnect and secure all turbocharger air induction components.

15. Drain and replace engine oil and oil filter, as stated in Section 6J-2 for turbocharger replacements.

16. Reconnect battery.

17. Start engine and check all oil, coolant, air induction, and electrical connections that were disconnected during the course of servicing. Check thermostat and turbocharger operation.

Labor Operation Number: T1380 Labor Time : 2.7 Hour without A/C 3.1 Hour with A/C

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.