http://www.angelfire.com/ri2/turbominivan/
twogsinfaggella@cox.net
http://www.angelfire.com/ri2/turbominivan/
twogsinfaggella@cox.net
Turbo second generation - the ULTIMATE sleeper! You'll baffle even the turbo dodge experts.
There are many things you must understand first.
Wiring:
Possibly the hardest thing you will ever do in your entire life, or so it was for me anyway. I had a 1989 Minivan Turbo wiring harness that I had to have converted. Why converted? the bulkhead connectors were different. But the look similar? Okay, they'll fit, but the connections inside are different. For example, in 1989, the pin for the headlights might be the pin for the check engine light. So basically nothing would work. I hear that if you have a 1992+ wiring harness, it will go together fine, no problems, but I haven't had this verified so dont quote me on it.
Once you connect things, you will probably notice some un-used connectors. Do not panic. It may likely be the cruise control module, or extra turn signal lights that the first-generation Caravans had.
what you will need:
The engine, duh.
complete wiring harness and computer
ALL associated sensors. (Wastegate, barometric pressure sensor, MAP)
Sound easy?
A good sense of what's going on
A good engine hoist
TWO of every metric socket. (believe it or not, I dont think we used an open end wrench once during this engine swap.
Weeks of time
A garage. You don't want to be doing this in the cold.
I know there's more than this. When I think of it, I'll add to it.
Before Removing The Engine
Things to remove first, no particular order:
A/C condensor, and all associated hoses.
Intake. (shown here under Tony's arm)
Drain/Remove radiator. Careful, it holds alot of fluid.
Alternator
Exhaust (sawzall)
Coolant hoses going to the firewall (can be seen in the picture above, what Tony is tugging on)
Battery tray/Battery
Wiring harness and computer
Windshield Washer bottle
Radiator/All associated hoses/overflow tank
Removing The Engine
Remove the middle engine mount. It should be a few 15mm bolts.
Put a jack underneath the engine.
Remove the side engine mount. It should be two 15mm bolts, one LARGE (19mm?) nut on the bottom of the mount, followed by a few more 15mm bolts on the engine.
Put another jack (or jackstand) underneath the transmission.
Start taking off the starter. It should be one 15mm nut, along with 2 more 15mm bolts.
Next start removing the transmission bolts. There should be 7 of them, if I recall correctly.
Wrap a chain or straps around the engine. The power steering bracket is a good place to attach the straps. The throttle body is another good spot. Remember, these engines dont even weigh 250 lbs, so it doesnt really matter where you grab it from. Forklifts are great if you can get your hands on one.
