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I did a ton of work on the 90 745t this weekend. Here's a list of what I did:
Water pump
Thermostat
Radiator hoses (3)
Heater hoses (2)
Heater valve
Motor mounts
Oil cooler and adaptor orings
New harmonic balancer
New accessory belts (3)
Everything went very smoothly and no leaks (knock on wood). I have a ton of questions and some observations for others...
Motor mounts: The turbo side was extremely simple. Take all the intake hoses off and unmount the power steering pump and you have superb access to all the nuts except the one bolt that has to be accessed from under the car. The drivers side was a headache. What is the trick for the inner front nut on the lower mount bracket??? Maybe one of those new rachet box wrenches???
Oil cooler and adaptor orings: I had bought two of the black and two of the green just in case. I used one of each! The oil cooler was a black one and the adaptor was green (IIRC). When I bought them the parts book listed both for my year and didn't give any indication as to which would fit...
Cooling system: My water pump was leaking out of the top seal (bad front seals that were fixed with the timing belt were slinging oil up there). Everything went smoothly. The thermostat was broken in the usual way. Car heats up super fast now!
I didn't replace the turbo oil return pipe seal yet. The bolts hold it to the (Mitsu) turbo are hex keys, not regular bolts. Any easy way to get these off? I'm thinking that I'm going to try cleaning it up really good and sliding a new seal in with some high temp silicon and calling it good rather than risk doing something that will require pulling the turbo.
With the new pulley on I noticed something a bit odd... looking at it with a timing light as the throttle is smoothly advanced the timing moves smoothly, reaches a "stable" point, then seems to jump as the throttle is advanced more. Is this a normal part of the ignition timing map? Bad knock sensor? Bad gas????
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