1996 850 Intercooler brackets - how do they attach?

T64me · Post by **T64me** » 04 Dec 2014, 10:00

I am in the process of replacing the radiator on my 96 Volvo 850 Turbo with 166,xxx miles. I removed the radiator last night and found that the left/right side brackets on/plates on the intercooler are not attached.

I would think they are supposed to be tack welded in place, but they are not. Are these brackets supposed to be separate from the intercooler? If they are supposed to be attached, any suggestions on how to reattach them?

Thanks in advance for any constructive input.

Post by **xHeart** » 04 Dec 2014, 10:25

Cooling System diagram may help a little http://volvopartslisle.com/catalog/1996/850/61/2/2/1996-Volvo-850-Automatic-(B5234T5)-2.3L-Turbo-OEM-Parts-Diagrams

T64me · Post by **T64me** » 04 Dec 2014, 10:36

Sadly I cannot find the diagram. My guess is if I did find the diagram I would see how the brackets are oriented - that much I know.

My question is how do they attach? Are they welded in place?

Post by **scot850** » 04 Dec 2014, 15:39

On the cars I've had (850 and V70) they are originally just glued on if I remember correctly. They can mount either way around, but you have to watch which way up they go due to other things that mount to them (at the bottom I think).

The last time on my V70 XC, I remember there were what look like little teeth on the side of the intercooler. I carefully bent these over into the holes in the brackets. You can also use some thin double sided tape to hold them in place.

Sorry, don't have a picture of them fitted.

Hopefully you can see enough from the ipd website picture of an OE intercooler to figure out.

http://www.ipdusa.com/products/9381/120 ... 70-v70-c70

Neil.

Neil.

T64me · Post by **T64me** » 04 Dec 2014, 17:41

Thanks for the input and the link!

Post by **Atis** » 05 Dec 2014, 05:05

One of my friends had a problem that the brackets were loose and the IC was wiggling between the radiator and the climate heat exchanger. He noticed that because of a hole on the IC.
An official Volvo mechanic repaired him somehow (within 5 minutes or so).
I will ask him and report back.

P.S: mine is just started to became loose...

T64me · Post by **T64me** » 05 Dec 2014, 07:47

My IC and brackets are out as I am replacing the radiator. I am thinking about using epoxy to put them back together. Curious how the mechanic fixed your friends car.

T64me · Post by **T64me** » 05 Dec 2014, 20:27

As I worked on this project again tonight I could see that the brackets had originally been glued in place. I used emery cloth to rough up the old glue, applied some JB Weld to reattach them. I used vice grips to hold them in place while the JB weld dries - should be ready in the morning to reinstall.

Post by **jreed** » 06 Dec 2014, 06:01

I posted below a sequence of photos I took while removing the intercooler from the original (cracked) radiator and transferring it over to the new radiator, positioning and tightening the clamp plates that hold the intercooler to the radiator.... It's been about 18 months since I did this work so I can't remember how the clamp plates fit into the intercooler. Hopefully the pictures will be of use...

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