OK, I really did it to myself this afternoon. I was replacing the oil drain line gasket at the flange connection to the turbo unit and happened to over-tighten one of the bolts to the point it twisted off (broke). I now have the oil drain line flange held in place with only one bolt. I've uploaded a photo showing this. The only way to get the remaining bold stud out of the turbo unit will be to remove the entire turbo unit from the engine and drill it out or use an 'easy-off'. Does anyone have a good procedure to remove this portion of the turbo unit without taking off the entire exhaust manifold? I am not looking forward to this repair job. There seems little room to move and get wrenches in there. I hope someone can provide some insight to this.

 

i'm thinking turbo out, easyout or drill out bolt, no fun.

you should be able to unbolt the turbo from the header, and from the downpipe and take it out. lots and lots of Kroil on those rusty bolts, plan on replacing most of them.

 

Thanks for the encouragement Pierce. I ordered some parts - gaskets just in case needed and won't start the job until I have these in place - likely near end of week. Biggest problem might be to find the right size metric bolts. I'll post when job is complete or I run into other problems.

 

the correct bolts should all be available from Volvo, if you order them from a place like tascaparts.com or volvopartswebstore.com they aren't even that expensive.

assuming you have a mitsubishi turbo w/o EGR...

(4) studs to connect turbo to exhaust manifold: 1336261
(4) lock nuts for studs '' : 977209
(3) studs to connect exhaust downpipe to turbo: 1357769
(3) flange nuts for '' : 948645
(2) hex screw(bolt) to secure oil return to turbo: 942001
(1) washer for oil return into block: 1306264
(4) gaskets for coolant line banjos: 947282
(2) gaskets for upper oil fitting banjo: 947282
(2) gaskets for oil fitting banjo into block: 947621
(1) gasket for oil return line into turbo: 3514546