Let's talk turbochargers

[jblackburn]

In other news, I've got most of the intake manifold bolts off, but it's still not budging. I'm following the PCV replacement thread for guidance. I'll get it eventually. I've actually removed the more tricky bolts underneath. Still tracking down the remaining few...

You got the two up under it? Then there's only 7 up top - other than that, it should come right off. I remember tugging on it and being like why the HELL won't it come out, then realized i missed the main one that holds it to the bracket underneath

It looks to me like you're right about the actuator. Did you try spraying the heck out of that nut with PB blaster? Mine was pretty rusted, but it came loose within 2 shots of that stuff.

[j_cd]

I just got it! I had missed the bolt behind the PCV oil line that runs to the head. So it looks like I have to remove that hose at the top and route the manifold up and over it. I see the oil trap.

[pkc303]

That is so much fun, I did it twice recently on both of our 850's. It's a great feeling when you get it all back together.

[j_cd]

Looks like I should detach the wires and take this manifold out for a thorough Seafoam cleaning. How do you remove the fuel injectors? It didn't seem like a great idea to just pull up on the rail until the gaskets popped out of the manifold. so I didn't do that.

[vjaneczko]

Since you have it apart already, might as well use carb cleaner first, then run seafoam for the rest of the system once its back together.

[j_cd]

OK I've removed the intake manifold completely from the engine. I put some tape over the electrical connections, then sprayed with carb cleaner and scrubbed with a toothbrush. Drain, spray again, etc...

Looking at this picture of a new turbo actuator, it's easy to replace. For some reason I thought you had to remove the pop rivet on the end of the actuator rod, but you just pop the clip and that's all.

http://cgi.ebay.com/ebaymotors/ws/eBayI ... K:MEWAX:IT

[j_cd]

Just went to pick up my Complete PCV Kit from IDP. The box felt suspiciously light. Sure enough, there is no oil trap in there. Ugh. I was hoping to get this baby on the road asap. Now it's gonna be well into next week. Plenty of time to clean parts I guess. Had I not cracked the lower left bolt off the old oil trap removing it I would use it. Major setback. Now I'm gonna start forgetting how this thing goes back together.

I was going to get an oil trap from the Volvo dealer today, but I've also got a t bolt clamp that doesn't have a bolt. I'll just wait until next week when the correct parts are all here.

Strangely, my PCV kit has a bag with 10 small black o-rings. These are not listed in the kit, and I removed no o-rings when I took the pcv apart. Maybe whoever shipped my kit didn't know and got that part number mixed up with the oil trap.

[j_cd]

I found this page here with a wealth of information on volvo turbos.

http://www.vcoa.org/700-900-faq/EngineT ... eplacement

According to this, the way to remove a Mitsubishi turbo is to undo the band clamp and separate the turbo from the wastegate, leaving the wastegate attached to the exhaust. That seems a lot easier than removing the whole thing. I tried this, but it didn't budge. I think you have to pry the sections apart. I don't want to break the turbo, so I re-tightened the band clamp for now.

Let's see, what else? I've lost 1 of the 3 little hex bolts that hold the CBV. Autozone has some flanged hex bolts in that size that aren't identical, but should work if necessary. I may replace the stock CBV with this Forge Recirculation Valve anyway. I'll find out Tuesday if it comes with new bolts. One place sells it for $135.

http://www.forgemotorsport.com/content. ... t=FMMIEREC

The actuator moves just fine, so I'll probably leave it alone. I may replace the lines that go from the turbo to the oil cooler though. I don't want to, but probably should.

[j_cd]

To take out the actuator, simply remove the clip at the end of the rod, and the two 12mm bolts on the housing.



This actuator does sound a little squeaky. If I don't end up replacing the turbo I'll put a brand new one on. Here's the turbo air intake with the CBV removed.



I think one reason the turbo wouldn't budge last night is because the coolant banjo bolts are still attached. So the next step is to drain the coolant and take those off. Loosening the band clamp should allow better access to the upper banjo bolt.

[j_cd]

Removing the coolant and oil lines are further down the rabbit hole than I care to go right now, so I left the banjo bolts alone. Gave the turbo housing a good cleaning instead.



Found that missing CBV bolt, so I reinstalled the CBV.



Found this awesome Volvo logo underneath the gunk!



Here's the cleaned actuator ready to be reinstalled. I put some 3 in 1 Oil on the rubber boot where the actuator rod goes into the housing. It's slightly less creaky now.