MVS Forums member bugs11 needs some tips and “best practices” on installing a turbocharger into his 1996 850:
I’m ready for a turbocharger install on my 1996 850 project. So far the only tip I’ve gotten is from a diesel mechanic who said to put oil into the turbo body before installing it. I have the Haynes manual, which is what I’ll go by unless someone has a better idea.
Be careful with the o-ring on the oil drain pipe. At first put the ring on the end of pipe, grease it slightly with engine oil and then install pipe to the drain hole in cylinder block, then screw pipe to the turbo body . Doing it in other order (put the ring in the hole, then install pipe) you will damage o-ring for sure.
You can get the CBV diaphragm from lots of places, but I would make sure it is made by Mitsubishi. I have seen posts recently about people getting new CBVs that leak immediately or soon. I have bought them on eBay in the past but it is getting tougher and tougher to buy there and not end up with junk.REMOVE / INSTALL / OVERHAUL – TURBO
1995 Volvo 850
1995 ENGINE PERFORMANCE
Volvo – Removal, Overhaul & Installation
850 – Turbo
Removal, overhaul, and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.
WARNING: Always relieve fuel pressure before disconnecting any fuel injection-related component. DO NOT allow fuel to contact engine or electrical components.
FUEL SYSTEM PRESSURE RELEASE
1) Remove throttle pulley cover. Remove shield over valve on fuel rail. Connect Adapter (999 5484) to Fuel Drainage Unit (981 2270,
2273 and 2282). Connect adapter to valve on fuel rail, ensuring adapter is in locked position. Start fuel drainage unit. Unlock adapter. Raise and support vehicle.
2) Remove fuel filter valve cap located under vehicle.
Connect Vent Hose (999 5480) to valve before fuel filter. System drain time is about 2 minutes.
Removal & Installation
1) Fuel pump is located in fuel tank. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. On station wagon models, lift
luggage compartment floor cover and fold back carpet. On sedan models, tilt right rear seat forward. On all models, remove luggage
compartment carpet and right wheel housing panel.
NOTE: On some versions with a soft panel, it may be sufficient to fold back a corner of the panel.
2) Remove cover above fuel pump collar. Disconnect fuel pump connector. Carefully disconnect quick-release couplings on delivery and return lines. Remove fuel pump collar. Lift out fuel pump. Remove rubber seal. To install, reverse removal procedure. Tighten fuel pump collar to specification. See TORQUE SPECIFICATIONS.
WARNING: If fuel pump is removed for a long period of time, reinstall fuel pump collar to avoid tank swelling. If collar is not reinstalled, it may be difficult to install at a later time.
Read more: http://www.volvotips.com/index.php/850-2/volvo-850-s70-v70-c70-service-repair-manual/how-to-remove-and-install-a-turbo-of-the-volvo-850/#ixzz6MfCFrYhC