With all the serious repairs out of the way, it's time to fix the annoying putt putt on the 82 245 GLTi. I've got a stripped mainfold stud and can handle retapping the hole I think. Just need some advice on the removal of the manifold, Do I take the turbo off or can I leave it on? I'm gonna replace the O2 sensor while I've got the manifold off, anything else I should think of "while I'm in there"

Thanks
Bob
82 intercooled turbowagon 234K

I just did this job on my 82 turbo. I recommend jacking up the motor a bit to make it much easier to remove the turbo and manifold together. You can't separate them until they are off the car. I used Timesert inserts on the stripped and broken studs my car had. They work great and they are a bit stronger than just going into the aluminum head. Also, you want to make sure you have all new flange type locking nuts for installation. Otherwise, you may have fasteners coming loose and causing the same leaking gasket problems. The exhaust studs are special steel alloy for the high temps. Make sure you put the correct side of the gaskets out. The metal side, sometimes they are marked UT. I did this job three years ago and it came loose because I didn't know about the flange lock nuts. I bought new ones from a metric supplier called Maryland Metric. Also Electro Fast in PA has these kind of fasteners. I put the jack under the motor where the alternator bracket bolts on. Take your time, mark things if you aren't sure and bag fasteners and bolts. I did mine over a few days because while doing this job I also did a few side jobs like repair work the turbo needed and I took the head off so I could repace the head gasket. Wish you well. The boost is worth it.

Dave 82 242ti 276k mi.

Dave, Thank you! this information will prove to be very helpful.

More questions. I found Timesert on the web. Can you remember which kit you bought? Here's a link to the metric page
http://www.timesert.com/mtrcsert.htm

Can you use the regular size Volvo studs once you insert the holes? Do I have to get new studs from the dealer? Dealer is 200+ miles from here so I'm gonna have to get the studs/inserts/nuts shipped from somewhere.

Think I should replace oil return line from turbo while I'm in there?

Thanks for the words of encouragement. I share your sentiments about boost. I cannot think of another car I would have put as much work into as this one. I'm thinking that when I get all this stuff done, I might actually be able to drive 10-20K miles without getting greasy every weekend.
Bob
82 intercooled turbowagon 234K

Volvo also sells the proper flange-type metric copper-plated nuts for the exhaust. Yeah, they get list price but what the hell, you never want to do this job twice. I think they're all of 90 cents each.
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Rob Bareiss, New London, CT 86 244, 87 244, 88 744

I just went through that whole ordeal, but for a 244Turbo I'm parting out. I had had the turbo rebuilt so I wanted to save it. It's not only easier to remove the manifold/turbo as a unit, but under the heading of "If it ain't broken, don't mess with it" or something like that, turbo seals, gaskets, etc. can cause more headaches than manifold gaskets, which you'll be doing anyway. You will of course have to remove all the turbo hoses, etc. The only possibly difficult area is the connection to the cat converter and its integral pipe. You may have to loosen the exhaust system down the line to get some play. Good luck.

Jim Weiss
83 245T, 90 760TI, 93 940TI wagon, and still looking . . .