Well with some help from my son, I was able to get the turbo changed out yesterday. Some thoughts on changing out the turbo at least the Garrett T25.

Removed six nuts on the exhaust manifold and removed the shields for the spark plug wires. This allowed easy access to the nuts fastening the turbo to the exhaust manifold. The three nuts holding flange for the exhaust down pipe to the turbo came off easy. The four nuts holding the turbo can off easy. That left disconnecting of the oil down tube (clean inside), the oil supply line and water supply line.

Getting the turbo loose from the exhaust manifold was far easier than I thought.
It was far more difficult getting the turbo out as the bottom stud that holds the flange for the exhaust down pipe kept interfering with the ability to remove the turbo off the studs on the exhaust manifold. Finally, with enough prying, we were able to get the unit out.

Putting in the other turbo from my 940SE sedan proved to be a lot easier. The biggest help was the lack of the bottom stud. The stud came out when I took the flange holding the exhaust down pipe in place to the turbo housing.

I found that it was much easier to install the oil drain pipe (new gasket) I was able to get new copper rings for the oil supply line banjo fitting but had to reuse the ones for the water supply line. So far no leaks have appeared on the water supply line.

The engine is performing up to expectations and I am very happy that things went well. I have had bad experiences in the past with nuts on exhaust system and have wrung off many in my time but never on a Volvo.

This job would have been alot easier if the designer of the bracket support for the exhaust manifold and used some common sense in the design. There are several ways the design could have been more mechanic friendly. This way the exhaust manifold and turbo could be changed out as a unit. I plan on making changes to the bracket so the manifold and turbo can be installed together.

91 940SE Wagon, 940SE Sedan(waiting for an engine transplant) and 99 300M