Professional installation recommended. Pro Xe Automotive recommends installation by a qualified professional or highly experienced individual familiar with turbocharged Volvo P1 vehicles.
Correct installation is critical to proper operation and long-term reliability.
1. Access and Intake Removal
Choose your access method before removal. FWD: removing the front passenger CV axle provides the best working room. AWD: removing the front passenger axle and Haldex angle gear is
recommended. Top-side removal is possible by repositioning the engine after removing/loosening mounts, but we have found underside access easiest. Remove the turbo intake ducting and intercooler/charge piping.
2. Remove the Heat Shield
With the intake tube removed, remove the four 10 mm fasteners securing the heat shield. Carefully lift the shield away without bending nearby hard lines.
3. Disconnect Coolant Lines and Oil Return
From below, remove the two 19 mm banjo bolts securing the coolant feed and return lines. Expect some coolant loss. Remove the two T30 Torx screws securing the oil-return tube and separate it from the turbo. Install new copper sealing washers on the coolant fittings and a new oil-return gasket during reassembly.
4. Disconnect the Turbo Oil Feed
Use a 15 mm wrench to remove the oil breather fitting as required for access. Remove the 17 mm banjo bolt securing the oil feed line to the turbo cartridge. A small amount of oil may drain. Replace the copper sealing washers on both sides of the banjo bolt.
5. Disconnect the Engine Side of the Oil Feed
Disconnect the opposite end of the oil-feed hose before removing the turbo assembly and position the line safely out of the way. During reassembly, route it without kinks, twists or contact with hot exhaust components.
6. Disconnect the Exhaust Pipe
Remove the three 10 mm fasteners securing the exhaust/downpipe flange and pull the exhaust away from the turbo outlet. If corroded, apply penetrating oil and allow it time to work before forcing the hardware.
Once all fasteners are free, slide the turbocharger/manifold assembly off the cylinder-head studs. For additional removal clearance, Pro Xe Automotive recommends removing the front passenger-side CV axle rather than repositioning the engine or removing the engine mounts.
We have found the easiest removal method is to pull the turbo assembly rearward, then rotate it into a more vertical position while raising it as needed to clear surrounding components. Once properly oriented, bring the assembly back down and guide it out through the clearance created by removing the passenger-side axle.
During reassembly, install a new turbo/manifold-to-cylinder-head gasket and verify the assembly is fully seated before tightening the manifold hardware.
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