Howdy yall, I started turning my '83 244t project car into a '83 244ti today, and have found it's not as simple as it once seemed. The intercooler itself fits fine between the condensor and the radiator, but the end tanks and hoses do not. On the driver side the flared top of the tank hangs up on the oil cooler, and on the passenger side the tank looks like it'll clear, but the intake hose looks like it's routed directly in the path of the coolant recovery bottle. Needless to say this won't work, unless of course I just drive without a hood, which might be cool. So is there some way that I'm supposed to relocate the oil cooler? If so, where to? How about the coolant recovery bottle? I can say with fair certainty that the intercooler is off of an '85 B21FTi, since Lennart owns the engine, says that's what it is, and the intercooler was sitting right next to it.

Also, I know that I'll need extended upper and lower radiator mounting brackets (pretty sure I can use 740ti parts for this), but what else will be necessary? Will I really need a special switch which automatically increases the boost at high revs, or can I just set the boost to the factory 10 or so psi under all conditions? Also, on the output hose on the driver's side, just as it exits the intercooler, there's a nipple for some sort of attachment. What is that thing? Can I just plug it up? Finally, the intake throttle body that says "turbo" on it is facing toward the passenger side of the car, and the intercooler hose is designed to connect to the intake of an intercooler model. The intake on the intercooled engine looks to be aimed toward the front left corner of the car. Can I just unbolt and rotate my current intake? Do I need to use the intake from an intercooled model?

Thanks a lot for all the help guys. The project is moving along nicely because of this place.

BTW I'm thinking of naming the car the Zombie to pay tribute to its having been brought back from the dead. Opinions?

See if this page helps:

http://www.geocities.com/MotorCity/Speedway/2204/int.htm

There's also a picture of the IC kit in the IPD newsletter from July/August '01.
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Michael -- 1987 244 GT | Volvo 240 Links

Yeah, a good IC kit will include the coolant bottle from an IC car as well as the mount bracket. Also, the upper oil cooler bracket is different. For the radiator IC brackets, the metal and liner are needed for the tops as well as the stiff rubber bottom bracket pair. 700T brackets are very close and uppers need a bit of bend to work. On the intake, you should have the 90 degree steel elbow that replaces the turbo "hat". The nipple runs a long hose over to a T fitting off the wategate. I would check into that. I think you can toss the boost solenoid apparatus. I can't tell if mine is in or out of the system, judging from performance, when I play with it. If you need any of the stuff I think I might have some extras. Best if you can find an IC 240 car.

Thanks a lot for the advice. I successfully completed the conversion yesterday. I still need to find the coolant bottle somewhere though. I'll probably salvage it from some bizzare non-volvo. It's too bad there are NO intercooled 240 parts cars around here, because the job would be a lot easier. I might drive the car today and calibrate my boost guage with an auxilliary pressure guage along side it. Once again thanks for the help.
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Isaac Babcock - '83 245DL 'Borkie' and '83 244 turbo project

I think IC cars used a different bracket to mount the oil cooler out of the way. The coolant recovery bottle is different, Its a smaller round cylinder that mounts sideways.

Aye, the overflow tank is similar to a tank from a 700 series Turbo, but it's smaller and slides into a bracket mounted to the RH strut tower.

- alex