How difficult is intercooler replacement.

Moppman · Post by **Moppman** » 19 Feb 2018, 04:53

So for a while I’ve had an issue of lost power and unable to drive the car without the maf connected, only to find out it was because the bottom intercooler housing had been smashed to hell leaking every bit of boost from the turbo.

Well I went out and bought a perfectly used on from the same year s70 and I plan to replace it today (currently 6:52am) but was curious on how difficult this is? I found an instruction PDF on here that I will take advantage of but curious on any tips or tricks.

Volvo S70 GLT
143,XXX

Post by **scot850** » 19 Feb 2018, 07:58

First thing is you should have sprayed the 2 radiator mounting bolts from the top for a couple of days as the bolts tend to get rusted and seized. When you try to undo them they can either break the welded nut off or the bolt head will shear. The first option can be got around with some help and fitting a regular nut, but the other requires more work to remove the thread remaining, but you may be able to do so from the top with a lot of penetrating oil and vice grips.

I support the whole assembly with a floor jack to support it using a long piece of wood but be careful to balance it so as to not damage the AC lines.

Does your replacement intercooler have the 2 metal 'wings' attached (one either end). You need those as that is what holds it to the AC and radiator.

If not, I have used the tangs on the side to position it. They are only held on with double sided tape that falls off with time. I glued them back on with JB Weld and also drilled small holes and used the slots on the side with large head aluminum screws to hold it all together. Way stronger than OE. CHECK the orientation of the wings when removing the old one if they have come off!!!

Other than that is it straightforward. The 2 radiator mounting bolts are the hardest part.

Neil.

Post by **abscate** » 19 Feb 2018, 08:46

If you are pretty quick a half day for this job in driveway.

I would plan on all day, first time, or if you haven't done a radiator.

Sticking points

Radiator nuts as mentioned above.

Fan screws - removing these to make room for the sandwich took me an hour once.

Post by **cn90** » 21 Feb 2018, 19:35

- I just recently replaced the rad (using Nissens) in my 1998 S70 GLT with 190K.
Once you have the rad out, the cooler is easy.

- This is the DIY Rad for 1998 S70 GLT:
viewtopic.php?f=1&t=83695

Post by **850 LPT** » 22 Feb 2018, 08:27

abscate wrote: ↑19 Feb 2018, 08:46 If you are pretty quick a half day for this job in driveway.

I would plan on all day, first time, or if you haven't done a radiator.

Sticking points

Radiator nuts as mentioned above.

Fan screws - removing these to make room for the sandwich took me an hour once.

1+

But you don't really need to take the fan out separately, it will come out with the shroud even though it's tight.
I found this out after wasting an hour just like you

Post by **rspi** » 22 Feb 2018, 08:29