I got a closer under car look at the widening gap between the Turbo and the exhaust manifold and found the problem is the bolts were coming unscrewed- loose keepers, etc.. Well, if it weren't for the block and the manifold,, this would be easy to fix, but back to reality... Is there a way to get in there and tighten the bolts without removing the manifold. Looks impossible to me, but I'm not up on these things.

If I have to R&R, do I need to replace the studs- that is, if they don't break, the turbo bolts, and is there anything else in there I should preorder before I go in?

And where can I order the parts I need? Is Volvo the best source?

Rick

According to the Volvo green manuals, the 4 bolts that are loose can be reused if shorter than 3.5 inches in length, not including the head. Chances are at least one or 2 are stretched beyond this. $$$$$$$...the most expensive bolts you've ever bought.

Rick,

See if you can find this post in the arcives:

turbo rebuild 700 posted by Bobsinluv on Fri Feb 1 23:09 EST 2002.

What you are about to have to do just to tighten your turbo is enough of a pain in the neck that you may want to consider renewing the turbo also if your's has a lot of miles already. Then you would be good for another 150k+.

I just did this on my '88 745 with Mitsu TD 05 turbo. My turbo, with 151k mi, was working OK but there was a nice crack in the housing, so I put on a rebuilt turbo.

You'll need:
New exhaust manifold gaskets, good ones! don't go cheap on these.
I used all new manafold nuts.
4 of my studs came out of the head with the nuts rusted on, I replaced these studs with new ones.
All the metal washers for the water and oil fittings on the turbo.
O ring for oil return into the block.
Paper gasket for oil return line to turbo.
O ring for oil filter adapter. (easier to change now)
Metal washers for oil feed line to block fitting.
New oil feed pipe. (required if you get a new/rebuilt turbo, I'm not sure otherwise)
Locking plates (two tops, two bottoms)
Turbo to manifold bolts if your's are out of spec. I needed 1. It cost $25.
Exhaust down pipe flange studs (if needed; $12 each)
New hose from turbo outlet nipple to wastegate actuator. If needed; you do not want this hose to fail or overboost could occur.
Check all the hoses.

Do you have a manual? The mitsu TD 05 was not covered in any of mine but don't worry, the Haynes or Volvo manuals with the Garrett procedures are OK.

Tips: Soak the hell out of the exhaust manifod nuts with PK Blaster. I soaked mine for two weeks.
If you are going to reuse your turbo I would not seperate the turbo from the housing. There is a small locating pin on each side of the turbo center section. I seperated mine and one broke off. I could be very difficult lining everything back up with that broken. It's hard enough getting the oil return pipe on without any more agravatation.
When putting the exhaust manifold with turbo attached back on it will save you time if the oil return pipe is already attached to the turbo, BUT you will need a helper under the engine to guide it in the hole.
Make sure the parts guy knows the exact turbo you have, year , etc. Some of the washers are different depending on turbo.
Try not to break any studs! Take your time. If it feels bad let it rest and try later. After another soak. There is advice in the FAQ's about heat, nut crackers and other ways to do this.
There is a ton of good info in the FAQ's about this job.
Use anti seize on reassembly.

Parts: I got all mine from Swedish Engineering. They sell Volvo and aftermarket parts. Some of the parts were Volvo only, like the oil feed pipe. Swedish Engineering repairs Volvo's and they know what aftermarket parts are OK. I'm sure some of the other board sponsors are just fine too.

Take your time and this is an interesting job. It can be done.

Good luck,
Chuck

1988 745t 152k, 1995 945 111k

Dang- I was hoping there was a way to swing the manifold away from the block, just enough to get a wrench up in there. In my case, will I have to R&R everything to tighten the turbo mounting bolts? Are their substitutes for them, BTW? I don't mind the extra work - I just don't want to disturb what doesn't need removal.

And, if i find there is erosion between the mani and the turbo, is there a gasket that I can put in there? Just preplanning.

Thanks for the parts list. Since I am a ways from a Volvo dealer, I want to have everything here before I do the work


My garrett is in great shape- tight and no oil blow by; I suspect the previous owner replaced it about 60K miles ago- the reason for my suspicion being the exhaust nuts on #1 were also loose, and a couple of the other ex. mani. bolts were barely snugged up. I have been soaking the nuts with PB, then giving theme a little turn, just enough to move them, resoaking then retightening. Paranoid abuot breaking them to do this with a 1/4" drive to keep down the torque

And finally, if all goes well (blind optimist here) how long will it take to do the work?

Thanks for all of the input. I have done engine work on a Saab motor, so the work doesn't bother me, but I want want to knwo everything before I open the socket case.

Rick,

I don't see any way to solve your problem without removing the manifold.
Which means removing everything connected to it and the turbo.

These turbo to manifold bolts aren't anything like you'll find in your local hardware store. They really do look special. Maybe that's your problem- the PO used whatever fit from Acme Trusty Hardware. My 4 bolts were all within length but the threads did not look so good on one so I ordered a new one. I was surprized when I got the bill and it was $25. It did not come with a VOLVO tag so I don't know if it was a VOLVO only part or not. Swedish Engineering probably gets them by the box. Or the dealor they get Volvo parts from just sent one bolt from their box. Anyhow, I wouldn't fool around with a less than top quality bolt. This isn't a job you want to do again in 6 months.

Cross your fingers about the mating surfaces. There is some mention of this in the FAQ's, I think. Or the archives. Volvo did not use a gasket. Worst case is a trip to a machine shop to get it smoothed out. One guy said he did it with a file. He's better than me! One guy said something about a stainless steel gasket. You see used manifolds on E Bay often.

I took a month removing and replacing my turbo. I'm slow! Some of the time was waiting for parts, and soaking nuts. I worked on it a few hours at a time, sometimes half a day. Fiddled with other stuff too- replaced distrubitor seals, cleaned throttle body, changed oil trap and put in low coolant light. This was my first turbo job. I could probably do it in a weekend now without problems or missing parts. One guy said he installed a turbo in two hours- that's fast.

It looks like the big question is how many turbo bolts will you need. Maybe the parts place will send you 4 and let you return the ones you don't need. Then you could press on with the job.

If I can find that referance to the mating surfaces I'll post the link later.

good luck,
Chuck

Thanks for the extra info. I spoke to a mechanic about doing the work, and he talked about machining both the Turbo and exhaust mani mating surfaces. I hope there is a gasket that will eliminate the need for this.

Thanks again, and I'll be checking for you reply.

R

Rick, here is some info from the FAQ's.

http://brickboard.com/FAQ/700-900/EngineTurbo.htm#ExhaustManifoldGasketandStuds

I read pretty much the whole turbo section while doing mine.

And check this thread: http://www.brickboard.com/RWD/index.htm?id=750888

I did not read all the posts but it may be of some help.

good luck,
Chuck

Chuck- thanks a lot for chasing this down for me. You saved me a lot of time. I will read it all today. I don't knwo if this is in the material you mentioned but I wonder about inserting a gasket between the turbo and the ex manifold.

Thanks again, and more as it happens

Rick

Rick,

We've gotten too far down the list to get any more fresh input.

>>>I wonder about inserting a gasket between the turbo and the ex manifold.

Sorry but i can't remember or find where i read about that. Pray that your's is Ok and if not ask in a new post where guys who know will see it.

good luck,Chuck

Hi,

Not an expert on your questions on the manifold, but on where to order parts, definitely always, always order them online. Huge savings!

Here are a couple of links

http://www.fcpgroton.com/volvo.htm


Here's another place that offers free shipping and $10 off on orders over $75 until April 30.

http://www.carpartsplace.com/?discountid=9943

It's a good idea to shop a couple of online sources since prices may vary

Good luck
JJ