- 1). Remove the turbo kit from its packaging, and lay out the parts on the floor. Make sure all the components are there.
- 2). Jack up your Volvo and place it on jack stands.
- 3). Disconnect the exhaust pipe from the exhaust manifold; there will typically be two or three bolts you can pull out with a ratchet. Then remove the bolts that connect the exhaust manifold to the engine block, and remove the manifold.
- 4). Install the turbo onto the new manifold, using the hardware supplied with the kit. Be sure to install a gasket between the turbo and the manifold.
- 5). Connect the exhaust manifold and turbo assembly to the engine with the hardware supplied. Torque the nuts to the torque specification supplied with the turbo kit. Connect the new exhaust supplied with the turbo kit to the turbocharger, or have an exhaust shop fabricate an exhaust.
- 6). Connect the oil feed line supplied in the turbo kit to an oil source on the engine. The source will be detailed in the turbo kit; typically it is at the oil pressure sensor.
- 7). Remove the oil pan on the Volvo, using the ratchet, and take the oil pan to a welder who will weld a bung onto it. This will be used for the oil return line. Reinstall the oil pan in reverse of removal, and connect the oil return line from the turbo to the oil pan.
- 8). Install the boost gauge (supplied with the kit) to monitor boost pressure. To do this, route a vacuum line from the cabin to the engine, and tap into a vacuum source on the intake manifold.
- 9). Flash the engine control module (ECU) so that it adjusts fuel and ignition timing to compensate for the additional air entering the motor. Failure to follow this step will result in severe engine damage. Buy a tuner and plug it into your OBD diagnostic port, and follow the steps given by the manufacturer. You can also ship your ECU to the company, and it will ship you a flashed ECU.
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