Went and bought a cobalt bit this morning, drilled and _carefully_ put some pressure on an easy-out. Stud started turning and came right out! Also had to use a Time-sert (fancy helicoil) in a different stripped stud hole. Was all ready to go back together and I ripped the dang turbo oil return line washer. Lucky for me, the nearest dealer is only 250 miles away and the little rubber part about as big as a hose washer only costs $9.50. So now I have to drive a Honda (ugh) until my parts come in.

Thanks to everyone who suggested to give it a try. I'm very happy the head didn't have to come off. Looking forward to the end of the putt-putt sound.

Bob

My cobalt drill bit tip from 5 years ago still lives!!

Right on - but man, an easy out? You live on the edge!

Good going!
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http://www.fidalgo.net/~brook4/oilslubesfilters.html

Pish posh. Pulling the head is actually pretty trivial. Just make sure you've removed everything first :-D

After that it's a whole bunch of rocking and prying, but nothing too difficult.

Have you contacted Borton Volvo in Florida? www.borton.com. They discount their parts a good 20% for everyone.

- alex

'85 244 Turbo
'84 245 Turbo

wow, thats pretty cool, glad everything worked out. What is this Time-Sert, is it different from regualar heli coils? I still have broken bolt (alt tensioner holder) in heli coil, thats still giving me a headache.

http://www.timesert.com/

Pricey. but a very nice repair.

Bob
'82 245Ti

oh oh, I like it. I think this is excatly what I need to fix my freaking 240 alt tensioner bolt so I can sell the damned car.

Mechanic said about anywhere from 150-300 bucks to fix the bolt, so I'm willing to try it as a last ditched effort.

Thanks.

Sorry, Bob--I don't want to make it out that I'm using you as an example of "what not to do", but I always, ALWAYS encourage people to buy two or three return line washers when taking the return pipe out for whatever reason. They are SO easy to rip, it pays to be forewarned and spend a couple of bucks to get a spare beforehand. I know I've posted this a few times before, but I can't remember when or in what thread. They're like rear main seals; I always have a spare sitting around because who wants to hose up the only one you have on a Sunday afternoon?

This is from experience. Not a down-the-nose sneer at other people in any way. I have broken these things. Rear main seals too--you only get ONE chance at getting that thing right, and the next time, it's FOUR HOURS minimum of labor to replace it. But probably more.

Again... I'm not pointing a finger at you. This just happens to be a good reminder for people to order a couple of those. I mean, a lot of people know what it's like to break the ONLY one of something, and not be able to get a new one. ANYONE (and I do mean anyone including service technicians) can break those. I've torn them too. Nobody is too good to rip one of those.

Congratulations on the rest of the project though. It's somehow very satisfying to finish a project RIGHT. Not just "finish" it.

Yeah, I'm kinda learning about this as I go. I was going to buy three of them but the dealer only had one :-( Hope this goes back together nice for me or I'm looking at another week of down time. Sometimes living in the sticks sucks.

Bob
82 245Ti

You make a good point. Keeping some extra gaskets on hand (like for the front seals, water pump, or turmp) is always a good idea.

Question is, where do you buy your gaskets for the turbos?

- alex

I agree with the spare parts. I am only my own garage, but my parts supply is something else. I almost always order two or three of an item because I screw up or lose something.

dick

You a lucky lucky man! Buy a lottery ticket today!

Glad everything came out all right. Job well done.
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Rob Bareiss, New London CT ::: 86 244DL, 87 244DL, 88 744GLE, 91 244: 808K total