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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
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abscate
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Re: Intercooler - repair or replace?

Post by abscate »

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!

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Re: Intercooler - repair or replace?

Post by bmdubya1198 »

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.
00 V70R Venetian Red/Charcoal M56 Swapped 200k
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07 XC90 V8 AWD Sport Titanium Grey/Black 174k
92 245 Base White/Beige 249k
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99 BMW 528i
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01 Mountaineer 5.0
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00 S70 GLT Mystic Silver/Taupe 253k
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Re: Intercooler - repair or replace?

Post by scot850 »

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
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Re: Intercooler - repair or replace?

Post by scot850 »

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 »

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.
00 V70R Venetian Red/Charcoal M56 Swapped 200k
03 S60 2.4T Silver/Black 118k
07 XC90 V8 AWD Sport Titanium Grey/Black 174k
92 245 Base White/Beige 249k
98 V70 GLT Black/Beige 205k
99 BMW 528i
84 BMW 318i
01 Mountaineer 5.0
Sold-
00 S70 GLT Mystic Silver/Taupe 253k
91 944 Turbo Dark Green/Beige 175k
93 944 Base Beige/Beige 221k
98 S90- Silver/Gray 207k
95 850 GLT Tropic Green... crushed
01 S60 2.4T Black/Black 230k
88 744 Turbo M46 Beige Metallic/Beige 188k
scot850
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Re: Intercooler - repair or replace?

Post by scot850 »

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
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Re: Intercooler - repair or replace?

Post by bmdubya1198 »

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!
00 V70R Venetian Red/Charcoal M56 Swapped 200k
03 S60 2.4T Silver/Black 118k
07 XC90 V8 AWD Sport Titanium Grey/Black 174k
92 245 Base White/Beige 249k
98 V70 GLT Black/Beige 205k
99 BMW 528i
84 BMW 318i
01 Mountaineer 5.0
Sold-
00 S70 GLT Mystic Silver/Taupe 253k
91 944 Turbo Dark Green/Beige 175k
93 944 Base Beige/Beige 221k
98 S90- Silver/Gray 207k
95 850 GLT Tropic Green... crushed
01 S60 2.4T Black/Black 230k
88 744 Turbo M46 Beige Metallic/Beige 188k
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