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900 Turbo 8-Valve Intercooler Installation

Home85Intercooler in 83Turbo | Before and After | Parts Checklist | Getting Started | Assembly

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Assembly page 2

 

  • Loosen all of the hoseclamps on the rubber bellows and turbo inlet pipe.
  • Remove the APC solenoid vacuum line.
  • Pull the deceleration valve from the rubber bellows.
  • Remove the rubber bellows, turbo inlet pipe and turbo grommet.
  • Cover the openings to the throttle body and turbo with plastic to keep dirt from entering.
  • Remove the air snorkel by loosening it's hoseclamp and pulling it from the front sheet.
  • Remove the flexible, warm-up pipe by loosening its clamp on the airbox and pulling it from its clamp on the exhaust downpipe.
  • Remove the "flapper box" that is clamped onto the airbox and discard. This is a preheater unit that will interfere with the intercooler installation.

 

removing the deceleration valve from the airbox. The flapper box has already been removed

Stick shift cars only

  • Pull the deceleration valve from the airbox as seen in the photo, disconnect the wire leading to it, and discard.
  • Find a suitable plug for the hole left in the airbox by the deceleration valve. The hole must be sealed airtight. A plastic plug with RV silicone sealant works well.

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Home85Intercooler in 83Turbo | Before and After | Parts Checklist | Getting Started | Assembly