Qeustion on fixing a 92 760 turbocharger

My brothers' 92 760 turbo wagon has had a loud exhaust leak since
he bought it from some motorheads in Houston. Somehow it has passed
two inspections like this. These guys said that they had taken the
turbo unit apart and it was in good shape. Well, yes, it does work
fine...but leaks. Apparently they didn't completely assemble the turbo
unit before installing it back in the car! Between the front part of
the turbo body which houses the inlet turbine, and the rear part which
connects to the exhaust manifold, there is a thick metal washer or
ring. Looking at the Haynes diagram, this ring is supposed to be a
complete ring, I guess this is a seal. However it is loose on this
turbo, and the entire upper half (180 degrees) is not there. I don't
know if they cut it, broke it off, or if it is supposed to be split
into two halves...and only the lower half was put in. Also, there are
four bolts (or maybe six) that do not go all the way through the
turbo, they go only through this washer between the two main halves of
the turbo and secure into the rear part. Well, there is only ONE
installed.... the three (or five) others are not there! So I told my
brother, well this has got to be where you exhaust leak is, its not on
the exhaust manifold or exhaust pipe.
We thought about just stuffing the cracks where it is leaking with
JB Weld....nope, some sharp-eyed inspector might see that, and that is
illegal. And besides, if he ever wants to get the job right, then the
cracks or bolt holes filled with JB Weld are a problem.
So he knows he is going to have to remove the turbo to fix the
botched installation. What we need to know is if there is a source for
this metal washer? Its circular on the inside ID, but on the outer
ID, the upper half (that is missing) looks like it is elongated, and
the end of the elongation, it's bent towards the rear at 90 degrees.
Also he would like to know what size are these bolts? 13 MM? and how
long/thread pitch? He would like to have the parts on hand before
removing the turbo. Haven't had any luck finding a junked 760 turbo
through the salvage yards here. Well gladly pay $$$ to get these
parts.

Thanks, Geronimo

 

Call a Volvo dealer for the washer.

 

The turbo will be the same on any 700 or 900 series turbo of similar
year. If you're missing parts though I would just buy new replacements,
the bolts and metal gasket are not terribly expensive. JB Weld won't
hold up to the extreme heat and might even catch fire which would be bad.