Las Friday my daughter tells me that the car is misfing and black smoke coming from the tailpipe.
I found 2 damaged (old, cracked) vaccum hoses next to the turbo. Fixed the leaks and problem continued.
She told me that the problem started after she drove on a driveway and the bottom hit. Looked underneath and the lower tank of the intercooler is detached. I can see that the whole thing is about 4 inches below where it should be.
Removed everything to find out that the two plastic "ears" that hold the radiator broke off and the radiator dropped as low as it could go. Of course, the intercooler is bolted to the radiator (The brakets were broken as well), and the A/C condenser is bolted to the radiator and so is the fan and shroud.
What a stupid, no brain, plastic, design.

Spent 2 days fixing the mess, I did not give my money to a Volvo dealer though. I spent more money at Home Depot thatn I did at the dealer.

I purchased a piece of 1 1/2" X 48" aluminum bar to fabricate a bracket that runs on the sides and under the radiator to support all the weight that was bolted, I riveted this and all the other broken parts, I re-assembled the intercooler lower tank and assembled everthing back where it belongs.

Have you had this problem?