Repair Procedure:

This procedure involves installation of the Overboost Control Kit and a revised engine controller.

1. Remove fresh air duct and air cleaner filter housing.

2. Remove by-pass valve vacuum line.

3. Remove upper intercooler-to-throttle body hose.

4. Remove oil drain back line and the PCV make-up air hose from the front of the air cleaner cover.

5. Remove air cleaner attaching nut from side of cylinder head.

6. Loosen the following hose clamps; turbo by-pass valve hose clamp at the bottom of the air cleaner, clean air hose clamp on the turbo inlet, and the by-pass valve vacuum harness clamp at the vacuum nipple attached to the turbo outlet.

7. Remove the air cleaner cover assembly.

8. Remove by-pass valve vacuum harness clamp and harness from air cleaner assembly.

9. Remove lower intercooler hose and tube assembly.

10. Remove engine controller.

FIGURE 1:

REFER TO FIGURE 1 FOR STEPS 11 THROUGH 18.
11. Install new lower intercooler hose assembly.

12. Attach by-pass valve hose to new upper intercooler hose.

13. Attach new by-pass valve vacuum harness to the nipple on rear of air cleaner cover and the nipple attached to the turbo outlet. Also attach harness to the 1/4" nipple on the front of the air cleaner by-pass valve.

14. Install air cleaner cover assembly.

15. Attach by-pass valve vacuum harness to vacuum tree at rear of the intake manifold.

16. Attach overboost control solenoid to the battery tray with new mounting screw and washer.
17. Install new by-pass valve hose to bottom of the air cleaner.

18. Install upper intercooler hose.

19. Install new engine controller.

20. Install air cleaner filter housing and fresh air duct.

Figure 2:

21. Install overboost control solenoid and wire harness assembly. Refer to Figure 2 for routing of the wiring harness.

FIGURE 3:

22. The two wire connector at the end of the harness routed to the solenoid pack on the right fender well should be connected to the EGR solenoid connector. The EGR
solenoid is not used on Turbo IV engines and the connector is taped back to the solenoid pack harness (Figure 3).
23. Connect the vacuum line at the boost gauge vacuum line elbow and at the "A" (top) port of the turbo actuator.


After the complete overboost control system has been installed, road test the vehicle. The road test must include four WOT (wide open throttle) accelerations in third gear from approximately 20 mph at 45 mph. These brief periods of acceleration will re-initialize the adaptive boost control memory in the engine controller.


WARNING: OBSERVE ALL LOCAL SPEED LIMITS AND LAWS WHEN PERFORMING THIS TEST!


POLICY: Reimbursable within the provisions of the warranty.