Biturbo Procedures

The following procedures are for a carburetor-equipped car with water-cooled turbos. In all cases, the battery should be disconnected and removed from the engine compartment.

Exhaust Manifold Removal from Heads

1. Remove air intake hoses and brackets.
2. Remove passenger-side charcoal canister.
3. Remove turbo plumbing to air filter housing and plenum.
4. Remove 13mm exhaust nuts using a combination of an open-ended wrench, box-end wrench, and flexible head socket wrench with extension. The studs may come out with the nuts. One or two nuts may need to be hammered off with a punch on the flats of the nut, or drilled off, as there is insufficient room for a wrench or socket.
5. Leave air injection manifold attached.

Intake Manifold Removal

1. Remove air intake hoses.
2. Remove spark plug wires with distributor cap attached.
3. Disconnect wiring to plenum solenoid vent valve and vapor pump.
4. Disconnect charcoal canister hose to plenum vapor pump.
5. Disconnect wire going into front underside of intake manifold.
6. Disconnect accelerator cable from plenum and lay it out of the way.
7. Disconnect automatic transmission kickdown cable from plenum (if equipped).
8. Remove oil vent breather hose connection to air filter housing. Leave hoses connected to the camboxes.
9. Disconnect turbo boost solenoid hose going to air filter housing ('R' hose).
10. Remove turbo plumbing to air filter housing and plenum.
11. Remove air filter element and housing.
12. Remove plenum vacuum hose to distributor advance assembly.
13. Disconnect passenger side plenum vacuum hose to fuel pressure regulator.
14. Drain radiator.
15. Disconnect left and right turbo coolant hoses in order to drain coolant from block (if water-cooled turbos) from underneath car.
16. Disconnect coolant hose, underside of intake manifold to multi T-piece connector in rear of engine compartment.
17. Disconnect vaccum hose to rear underside of intake manifold.
18. Disconnect fuel line feed to plenum; catch escaping gasoline.
19. Disconnect fuel line return hose at firewall on passenger side; catch escaping gasoline.
20. Disconnect coolant temperature sender wiring near thermostat housing.
21. Disconnect vaccum hose, front underside of intake manifold to T-piece. Disconnect adjoining vaccum hose going into underside of intake manifold and leading to the rear.
22. Unbolt intake manifold from heads; remove intake manifold gaskets.
23. Block intake ports to prevent debris from falling into cylinders.
24. Disconnect coolant hose from rear underside of intake manifold. Lift up manifold on passenger side to access hose connection.
25. Remove intake manifold with plenum attached.

Timing Belt Removal

1. Remove air intake hoses.
2. Disconnect wiring to fans and coolant temperature sender in the radiator.
3. Drain and remove radiator. Leave lower radiator hose connected at the radiator.
4. Remove air injection equipment (if equipped).
5. Remove front timing belt cover.
6. Position #1 piston at TDC; check timing marks on cam sprockets.
7. Block driver's side cam sprocket.
8. Loosen allen head bolt in cam belt tensioner assembly.
9. Compress tensioner spring.
10. Slip timing belt from cam sprockets and lay to side.
11. If removing heads, leave crank pulley and accessory belts installed. Otherwise remove accessory belts and block crankshaft using 1/4" square metal stock between the flywheel and the bottom of the bell housing. Remove crank pulley.

Cambox Removal

1. Remove timing belt (see above).
2. Remove turbo plumbing from plenum to turbochargers.
3. Remove oil vent breather hose connection to air filter housing.
4. Disconnect automatic transmission filler bracket (if equipped) from passenger side cambox.
5. Disconnect cable to knock sensor at plug connection.
6. Remove rear timing belt covers.
7. Disconnect wastegate hoses to turbos; lay to side.
8. Disconnect vaccum hose from vaccum chamber to thermo-switch.
9. Disconnect brake master cylinder wires and lay to side.
10. On driver's side, disconnect cable at plug going up to the firewall.
11. Disconnect distributor pickup at ignition control box.
12. Disconnect distributor retard vaccum hose.
13. Remove spark plug wires with distributor cap attached.
14. Remove cambox cover allen head bolts and cambox cover.
15. Remove cambox bolts in reverse sequence. Pry down on air injection manifold if necessary to reach bolts and use long hex socket (available from Baum Tools).
16. Remove cambox. Don't let cam followers fall out.

Head Removal

1. Remove timing belt, intake manifold, camboxes, and exhaust manifolds(see above).
2. Remove valve shims.
3. Disconnect coolant hoses to coolant housing on heads.
4. The coolant housings can either be removed (starter must be removed), or they can be left on. If they're left on, the head gasket will be attached to the head, and it might be harder to remove the head that way.
5. Remove head nuts in reverse sequence with engine completely cold. Remove head bolt washers.
6. Using a block of wood to cushion the blows, smack the front of the heads with a large hammer to break the seal.
7. Remove the heads. Use the air injection manifold to tug on the heads.
8. Make sure the exhaust manifold is clear of the exhaust studs. If the studs won't clear, then they can be removed with a suitable hacksaw, or they can be double-nutted and turned out.
9. Remove head gaskets.
10. With heads removed, disconnect coolant housings from heads. On water-cooled turbos, remove coolant flow restrictor plate from housing and note orientation of plate upon removal.

Power Steering Rack Removal

1. Jack up front of car; place jackstands securely underneath.
2. Disconnect steering U-joint from inside passenger compartment.
3. Disconnect tie-rod ends from steering knuckle.
4. Remove fluid from power steering reservoir.
5. Disconnect two hydraulic lines from underneath (19mm and 22mm box-end offset). Catch escaping fluid.
6. Remove 4 mounting bolts (13 mm swivel socket).
7. Remove rubber bushings and brackets.
8. To clear automatic transmission line, disconnect the passenger side hydraulic fitting (17 mm).
9. Slide rack out from passenger side first, then driver's side.

Door Panel and Window Regulator Removal

1. Close window fully, tape it securely.
2. Disconnect battery.
3. Remove two screws of door panel cover at lower edge, remove cover.
4. Remove four to five screws hidden underneath armrest.
5. Lift up inner door release handle, remove large screw.
6. Pry out inner door release handle.
7. Pop out switch on armrest.
8. Carefully pop out door panel all around its edge, remove panel.
9. Remove screw for door lock button, remove door lock button.
10. Remove three screws holding upper door panel to door at lower edge of panel.
11. Lift up upper door panel, remove.
12. Carefully lift off plastic shield.
13. Remove three 10mm nuts holding window motor to door.
14. Remove one 10mm bolt holding bottom of window regulator to door.
15. Remove two 10mm bolts holding top of window regulator to door.
16. Remove two 10mm bolts holding window regulator to window frame. A box-end ratchet helps here. A regular box-end wrench will do in a pinch.
17. Rotate window regulator and slide it out of the bottom of the door.
18. Remove screws holding window motor to window regulator.
19. Remove window regulator from door.