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Intercooler - repair or replace?

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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abscate
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Re: Intercooler - repair or replace?

Post by abscate » Wed Oct 05, 2016 1:20 am

Just get it as oil free and cleans as you can for JB weld...the magic elixir of broken kid toys. I still get the warm feeling when little ones comes crying with broken toy and next day it's magically back together...

It usually spellchecks to " abcess" Erik!

Abcise isn't a word I know , but abscise is a perfectly good pretentious word..." I was abscised after my wife identified the party in question as her sister."
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Re: Intercooler - repair or replace?

Post by bmdubya1198 » Wed Oct 05, 2016 7:29 am

Do what Robert did for the hood. Cut some of those rubber bumpers in half and secure them to the fan shroud. I used heavy duty double sided tape to hold them.
The hood still sticks most of the time, but I just have a little wedge I lightly push under the driver's side of the hood as I pull the release.
2000 V70R Venetian Red/Charcoal M56 Swapped 195k
2003 S60 2.4T Silver/Black 112k
2007 XC90 V8 AWD Sport Titanium Grey/Black 166k
1991 944 Turbo Dark Green/Beige 173k
1992 245 Base White/Beige 249k
2006 BMW 330i
1999 BMW 528i
Sold-
2000 S70 GLT Mystic Silver/Taupe 253k
1993 944 Base Beige/Beige 221k
1998 V70 GLT Black/Beige 199k
1998 S90- Silver/Gray 207k
1995 850 GLT Tropic Green... crushed
2001 S60 2.4T Black/Black 230k
1988 744 Turbo M46 Beige Metallic/Beige 188k

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Re: Intercooler - repair or replace?

Post by scot850 » Wed Oct 05, 2016 3:40 pm

Well took the intercooler to an aluminum specialist welding company and they reckoned they could fix it with no guarantee, but the unit needed to be cleaned to remove the oil residue from around the hole. So I took it to the radiator repair company I've used before and the guy took a look at it and apologised. He thought Volvo and though semi-truck. Their intercoolers are huge and thick so his radiator welding kit can't work on those. He took one look at the intercooler and said, he could fix it in a couple of hours and also flush the unit clean. They have done a nice job, and it cost me $100 CDN (about $75 US). A used unit from PnP is $75 CDN and I would have to pull it in 0C today with snow in the air. No thanks!

What I did find when I brought it home is there should be 8 tangs (4 each end) that hold the mounting plates in place along with glue. 6/8 of these are broken off! I'll clean the brackets off and reverse them as there are a matching set of 4 on the other half of the intercooler end plate.

The repair guys laughed when I told them about the hole in the bottom for draining moisture out, and just shook their heads! Got to wonder why it was not drilled at the lowest point at the intake pipe to the intercooler?

Neil.
2000 V70 R - still being an endless PITA
2006 XC70
2003 Toyota 4Runner V8 Limited
2015 Kia Sportage EX-L
1993 850 GLT -Sold
1998 V70 XC - Sold
1997 Volvo 850 SE NA - Went to niece in California - Sold
2000 V70 SE NA - New project and test bed - Sold

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Re: Intercooler - repair or replace?

Post by scot850 » Wed Oct 05, 2016 3:43 pm

Forgot to add that I have ordered a new lower hose as it is getting a little brittle and squishy at the lower end. I've also decided that as it is all in bits anyway to really have fun and replace the 2 turbo cooling hoses while everything is apart. Oh where is my hammer so I can start hitting my head so the pain will feel less when doing those 2 hoses!

Neil.
2000 V70 R - still being an endless PITA
2006 XC70
2003 Toyota 4Runner V8 Limited
2015 Kia Sportage EX-L
1993 850 GLT -Sold
1998 V70 XC - Sold
1997 Volvo 850 SE NA - Went to niece in California - Sold
2000 V70 SE NA - New project and test bed - Sold

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Re: Intercooler - repair or replace?

Post by bmdubya1198 » Wed Oct 05, 2016 4:09 pm

I still need to do my turbo cooling inlet hose. I've had a nice iPd hose sitting on the shelf for probably 8 months. The hose doesn't look too bad, but it's old and starting to deform.
2000 V70R Venetian Red/Charcoal M56 Swapped 195k
2003 S60 2.4T Silver/Black 112k
2007 XC90 V8 AWD Sport Titanium Grey/Black 166k
1991 944 Turbo Dark Green/Beige 173k
1992 245 Base White/Beige 249k
2006 BMW 330i
1999 BMW 528i
Sold-
2000 S70 GLT Mystic Silver/Taupe 253k
1993 944 Base Beige/Beige 221k
1998 V70 GLT Black/Beige 199k
1998 S90- Silver/Gray 207k
1995 850 GLT Tropic Green... crushed
2001 S60 2.4T Black/Black 230k
1988 744 Turbo M46 Beige Metallic/Beige 188k

scot850
Posts: 5938
Joined: Mon Apr 05, 2010 2:46 pm
Year and Model: 2000 V70 R
Location: Calgary, Alberta, Canada
Has thanked: 12 times
Been thanked: 211 times
Canada
scot850

Re: Intercooler - repair or replace?

Post by scot850 » Wed Oct 05, 2016 4:38 pm

I will have to crawl under the car to see them, and as it is an AWD it is even more of a PITA as the angle gear and prop-shaft block a lot of the access from below. I am hoping that access may be improved slightly from above by removing the air box and the intake hose to the turbo and the heat shield for the exhaust manifold. The 19T is a pig too as it is bigger than the 16T and 13G with even worse access.

I've had the hoses on the shelf for close on a year now!

Neil.
2000 V70 R - still being an endless PITA
2006 XC70
2003 Toyota 4Runner V8 Limited
2015 Kia Sportage EX-L
1993 850 GLT -Sold
1998 V70 XC - Sold
1997 Volvo 850 SE NA - Went to niece in California - Sold
2000 V70 SE NA - New project and test bed - Sold

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bmdubya1198
Posts: 3977
Joined: Tue Dec 30, 2014 10:45 am
Year and Model: 2K V70R M56
Location: Charlotte, NC
Has thanked: 44 times
Been thanked: 154 times
United States of America
bmdubya1198

Re: Intercooler - repair or replace?

Post by bmdubya1198 » Wed Oct 05, 2016 5:22 pm

Hahaha, I hate watching nice new parts sit. I have exhaust hangers lying around specifically for when I upgrade my exhaust, and it's been bugging me!
2000 V70R Venetian Red/Charcoal M56 Swapped 195k
2003 S60 2.4T Silver/Black 112k
2007 XC90 V8 AWD Sport Titanium Grey/Black 166k
1991 944 Turbo Dark Green/Beige 173k
1992 245 Base White/Beige 249k
2006 BMW 330i
1999 BMW 528i
Sold-
2000 S70 GLT Mystic Silver/Taupe 253k
1993 944 Base Beige/Beige 221k
1998 V70 GLT Black/Beige 199k
1998 S90- Silver/Gray 207k
1995 850 GLT Tropic Green... crushed
2001 S60 2.4T Black/Black 230k
1988 744 Turbo M46 Beige Metallic/Beige 188k

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