I ran it today. It started quick and ran smooth. It's intercooled and on its way to more power. Angel Morales' intercooler installation page was my advisor. Thanks to Michael for the link. I had to modify the installation procedure quite a bit, but it worked out with a couple of parts that Angel probably never thought could be used.

Of course what would this back-from-the-grave restoration/tuning project be without a few more snags. The radiator overflow nipple still precariously grips the top of the intercooler inlet. This seems destined to snap off if left in this position. It appears that Volvo knew this would happen, and didn't include how to deal with it in the intercooler instructions. I have the plastic tank radiator, and thusly cannot bend the nipple out of the way. I'm pretty sure that '81 and '82 Turbos had brass tanks, and the '84 and '85 intercooled models had the problem taken care of. Wouldn't that be ironic if I had the only year car that left this problem without a fix? Also, I'm having trouble locating a suitable small coolant recovery tank. The current one is in the path of the intercooler hose, so I had to unbolt it and sit it aside. I don't have a 240 or 740 turbo to take the tank from. Would a tank from an older car work? Ideas? Anyone know how I can get the overflow nipple on the radiator out of the way? Thanks a lot for the help. I'll be blowing away Pontiac Meras in no time.
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Isaac Babcock - '83 245DL 'Borkie' and '83 244 turbo project

Well.. I've never peeked at a non intercooled turbo... but for your needs it may be easier to adapt a tank from a 700 series turbo. The 240T IC coolant tank was designed to be held on with an L bracket. The 700 series tank (from a turbo anyways) is slightly larger but is held on by what appears to be a band clamp around a recessed portion of the tank.

As far as hoses go... the overflow tank to radiator hose looks pretty precarious on my 85 244 Turbo too. Again, I'm not sure if this is how it SHOULD look tho...

- alex

Hi Isaac,
You might try a recycling(junque) yard to get the correct coolant reservoir for the intercooled 240t. I got the whole setup for my 242t (tank, all plumbing, intercooler, turbo, etc.) from an upgraded wreck at the local pick n pull. If you are in the States try FCP Groton for a brand new coolant tank (I got one from them for my 740t) or try the dealer as a last resort...they can probably get the correct one for you. Have fun. I am hoping to have my 242t on the road this summer...I got sidetracked with our "new" 745t so the 242 temporarily got moved to the end of the line.


Dan

Sounds like your 244 was converted to have a 1984-on Volvo radiator. Should have a metal rad in it... Easiest thing is to either grab a pre-'84 rad or get a Nissens 3-row.
-J