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99 S70 Turbo Lines - Has anyone replaced the banjo bolts?

Help, Advice and DIY Tutorials on Volvo's P80 platform cars -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, including 850 R, 850 T-5R, 850 T-5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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Twarr12000
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99 S70 Turbo Lines - Has anyone replaced the banjo bolts?

Post by Twarr12000 »

Pretty much the title. The banjo bolt for the PCV under the intake is frustrating, but nothing compared to the turbo oil and cooling lines. I recently rebuilt my LP turbo and it took multiple attempts over several days to get the lines reattached. There has to be a better way.
I have been looking at using teflon lined braided hose and AN fittings to replace the inaccessible banjo bolts but I’m not sure it would be an improvement.

Coolant inlet - Easiest one of the four but it has the oddball hose with a different size on each end. Why? #9 in diagram. 12M 1.5 banjo bolt to hose connection.
Coolant outlet - Impossible to get a tool on if the oil inlet line is installed. 12M 1.5 Banjo bolt on turbo side to hose connection on water pump inlet pipe. #10 in diagram
Oil inlet - The one that gave me the most trouble. I apparently bent it removing the turbo and was very difficult to get lined back up. Very little clearance between the line, the coolant outlet line and the turbo volute. (It could’ve been a few millimeters longer and not hug the housing so tightly) It’s a rigid steel line with 12M 1.5 banjo bolts on both ends. The engine side is buried deep in a recess behind various coolant lines.
Oil outlet - Flange connection on turbo side, o-ring connection on engine.

12Mx1.5 to AN adapters are readily available. My initial thoughts -

Coolant inlet - pretty straightforward; AN6 on turbo side, compression fitting on the coolant pipe side
Coolant outlet - same as inlet, AN6 and compression fitting
Oil inlet - AN6 on both ends, possibly a standoff adapter on the engine side to bring the connection out far enough to get access for connecting the fitting.
Oil outlet - I don’t have an answer for this one yet. The o-ring side is problematic.

Has anyone attempted to improve these lines?
Anyone have any thoughts?

Edit to add - The lines are currently attached. I’m not going to mess with them just to be doing it. But if/when I have to R&R any of them in the future I would like to have a plan to preserve what sanity I have left.
IMG_2900.jpeg

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Post by abscate »

Start those banjos with new copper rings loose when you install the turbo. The just need a nip to seal when it’s in place. You will appreciate the ability to move the hard lines around installing the turbo
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1999-V70-T5M56 2005-V70-M56 1999-S70 VW T4 XC90-in-Red
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jonesg
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Post by jonesg »

a low profile ratchet from HF is the only tool I could get in there and remove banjo bolts.
From under the car.

https://www.harborfreight.com/14-in-38- ... 67994.html

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Twarr12000
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Post by Twarr12000 »

I have several 17mm wrenches, none of which will work on the coolant outlet. I would modify one by grinding, bending, whatever, but I don’t think there is a mod that would actually make it work.

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Post by abscate »

The (7) (8) onto the (15) pipe is a real bear - a clearance socket is needed to release.

It can be retightened with an open end.
Empty Nester
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1999-V70-T5M56 2005-V70-M56 1999-S70 VW T4 XC90-in-Red
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