VOLVO Factory INTERCOOLER Pictures and Information - 240 / 740 TURBO
by Anthony Hyde, Australia 2003

The Volvo Air-to-Air Intercooler

240/740 IC - Click images to enlarge

 

 
FROM 8/2005 According to literature, the Volvo 240 / 740 intercooler increases engine output by approximately 30 hp or 22.3 kW. Factory intercoolers were first fitted from 1983-84 (depending on model and country). Kits were available to retrofit to earlier 240 turbos.

Both the 240 and 740 turbos (1983.5-1991) share the exactly the same intercooler design, #1317319, being built by (Denso) Marston Ltd, in Shipley, West Yorkshire, UK. The design changed with the 940T around 1992 to suit a lower profile bonnet. The centre core matrix is a single pass design made from aluminium alloy, with end tanks of moulded plastic, painted black.
The core ends crimp around the end tanks compressing a seal. This seal is good for a maximum pressure of around 18 psi. Above this can cause the end tanks to leak or split.

DESIGN USE: Typical factory turbo 240/740 boost pressure varied from 7.5 to 10.5 psi being wastegate regulated.
A Turbo + Kit was an option on 740/940 models. This raised boost pressure to 13 psi (89 kPa). At full throttle, higher boost is held for a maximum time period of approximately 20 seconds.

CORE: Cooling core dimensions are substantial with a width of 466 mm or 18.5" & height of 430 mm or 17". This gives a core cooling area of 0.2 m2 or 0.65 sq ft.
Hot air from the turbo passes through through 34 horizontal cooling tubes, being rectangular in shape with no special features. Core tube width is a narrow 28 mm or 1.125" and tube height 3.1 mm or 0.125".

The intercooler is impressively light in weight at 3.3 kg or 7.3 lbs and gives v.g. cooling for its low mass.

The overall volume of the IC (with core & end tanks) is 3.5 litres (0.92 US gal). Pressure drop across the core is approximately 1psi with a 9 psi boost pressure, with the drop increasing with higher pressures being pushed through.

OVERALL INTERCOOLER DIMENSIONS: Height 440 mm or 17.500"; Width top 740 mm or 29" and Width bottom 580 mm or 23"; Thickness 60 mm or 2.375"; Air entry and exit internal diameters are both 57 mm or 2.250"; with outside diameter to suit a hose of 65 mm or 2.575".

Author 's comments: Consistent with design parameters, testing has shown the Volvo IC has very good cooling ability in the 10 psi boost region, even under track conditions. More boost = more heat and so above this boost level the intercooler metal core temperature rises and efficiency drops off. Motorsport testing shows at boost levels above 12 psi, after a rather long 20-25 second time period, heat soak into the core body reduces cooling efficiency below 60%. (Note a quarter mile takes between 14 to 15 seconds) Like all air-to-air intercoolers once hot, the core takes quiet some time to cool down again.

INLET

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Links:
 VOLVO GpA Intercooler pics (web page by Anthony Hyde, pics from Rolf Öhberg)
Hyde custom Intercooler - K&J core

Return to Anthony's Volvo Turbo World

Updated Sept 2003