How to Replace Oil Return Line on AWD Volvos

Need to Replace Oil Return Line on an AWD P80?

After about 4-5 hours under car I have the turbo oil return line disconnected at the turbo; old gasket (falling apart) removed.

Problem: Dealer sold me an orange O ring with the turbo oil return line gasket. Said it went into the end of line where it connects to the turbo. I can’t manage to get in into the end of the line because of really restricted, ugly access to that line

Does this orange O ring indeed go in the turbo oil return line?

Any tips on how to do the O ring at the side of the engine block, short of dropping the transmission?

FREE-PPV » I had just finished a valve job after water pump froze and timing belt came off, wiped out almost all valves, so bought another low mileage head and did a valve lap and valve seals, so here is my issue. Got it all back together and had major oil leak as the turbo drain pipe came out of engine? How in the world can this happen when putting on new head? Can’t get it back in hole, tried removing brace and loosening top bolts, a real hassle to access for sure, but still no go, just doesn’t align properly. So since it is out of hole, will replace O ring and gasket, but I still question why pipe doesn’t align with hole? Any tips on getting it back in, I assume you put tube in position first, but given the tight access to bolts, if they don’t align I am in deep shitz, so should I buy new pipe? Also, any trick in getting exhaust gaskets in, one was not in proper position behind turbo as you can’t see it.

renns » Sounds like you are making progress, but I know it’s a miserable job. I ended up pulling out the bevel gearbox on my AWD to give better access to the bottom of the turbo. That top bolt on the bevel gearbox was much tigher than the others in my case. With the passenger’s side axle shaft out, I was able to fit an air impact wrench with extensions, u-joint, and socket onto the bolt to finally break it loose.

As for fitment of the oil drain tube, I was able to wiggle it out, and back in, without much difficulty once the two mounting bolts at the bottom of the turbo are removed.

Replace Turbo Oil Return Line on AWD Volvos

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Last Updated on April 30, 2025