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Home >> Mercury >> 1991 >> Capri Base, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 1.3L 4-CYL - VIN [H] & 1.6L 4-CYL - VINS [Z,6] >> Removal & Installation >> Exhaust Manifold >> Removal (1.6L Turbo)

Removal (1.6L Turbo)

  1. Disconnect negative battery cable. Drain cooling system. Remove throttle body air intake tube. Disconnect intercooler hose from turbocharger assembly and position both intercooler hoses out of the way. Remove O2 sensor connector from its retaining clip, and disconnect O2 sensor. Remove lower heat shield and then upper heat shield. Remove turbocharger side heat shield.
    NOTE: Feed O2 sensor wire and guide through upper heat shield.
  2. Remove power steering pump (leave hoses attached) and lay aside. Disconnect lower radiator hose from water pump. Position power steering pump to access mounting bracket retaining bolts and nut. Remove both bolts and one nut, and remove bracket from engine. Remove 2 screws retaining air cleaner duct tube, loosen clamp at turbocharger and position duct tube out of the way. Disconnect coolant return hose at turbocharger. Remove bolt and brass sealing washers from oil supply line at engine block.
  3. Raise vehicle. Remove retaining nuts and washers from exhaust pipe flange. Remove 2 bolts retaining exhaust hangers to engine block. Slide off two rubber exhaust hangers at catalytic converter. Pull exhaust pipe downward and to LH side of vehicle. Disconnect oil return hose at turbocharger. Disconnect coolant return hose at turbocharger. Remove 2 retaining bolts from turbocharger support bracket. Remove 2 bolts retaining coolant by-pass tube outlet to water pump. Lower vehicle.
  4. Loosen retaining clamp bolt on coolant by-pass tube at rear of cylinder head. Remove 11 retaining nuts from exhaust manifold. Pull coolant by-pass tube bracket from exhaust stud, and position tube out of way. Grasp manifold, pull off studs and move assembly slightly to RH side of engine compartment to clear cooling fan, and remove assembly from vehicle.
  5. Working on bench, remove 4 nuts retaining turbocharger to exhaust manifold, separate assembly and discard gasket.
NOTE: When reinstalling turbocharger, thoroughly remove all gaskets and sealant. Use new gaskets. Add .85 oz. (25 cc) of engine oil in the oil passage of the turbocharger.
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