well, as it says in the subject, I am wondering how hard it is to add an intercoler system to a regular turbo? Also, what else has to be done to pump up the boost to 10-12 psi?? Is there a parts list and a step-by-step anywhere??

Any other thoughts??

I've done this on my 83' Turbo right after I replaced the turbo, and It's not overly hard to do. Make sure you have all the parts, and installation is pretty straightforward. I had to cut and bed the oil cooler bracket, and move it a little bit, along with replacing the coolant tank with the smaller version, and rerouting one of the fuel lines going into the fuel distributor. I also remember having to bend the top part of the radiator that connects to the hose that goes into the resivor up a notch.

I also added a manual boost control valve, and disabled the fuel cutoff switch (unplugged the vacuum line and plugged it up).

You will be happy when the car is intercooled, it makes a big difference. I also added a watercooling kit for my turbo at the same time.

Good luck,

Zack

PS: I used this site to help me through.

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


Silver 83' 242ti (i have finally began to fix the damage caused by the curb, and its contact with my left front wheel)

John-

IPD sells a complete kit for $595.00, if your interested give them a call
1-800-444-6473 \ www.ipdusa.com
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Bruce S. near D.C.

to get the 10-12 lb. boost you need the overboost cutout switch and the wastegate actuator from a factory intercooled car. i've been thinking about this modification myself, but since my turbo is so-so and increasing the boost is going to increase the leaking...
also, check out my ad in the classifieds.
jeremiah

That was true for intercooling 240 Turbos years ago, but I do believe most of these 240 Turbos have had their turbochargers changed over the years (along with the actuators). I have been told by turbo manufacturers that they only sell one version, instead of selling a separate turbo for and IC model versus non-IC model. So if the turbo (and actuator) was changed at some point, you will likely have an actuator compatible for intercooling.
Dave Barton

http://www.geocities.com/MotorCity/Speedway/2204/int.htm
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http://www.fidalgo.net/~brook4/oilslubesfilters.html

Well I dont think it would be that hard to do. I believe Volvo even made an aftermarket kit for such a purpose. However it is pricey. As intercoolers for the 240 series run anywhere from 400-800 USD. On the bright side you could purchase one on e-bay or from a pick and pull junkyard.

As for the other parts you would need I think it would just be the two alum. and the two rubber routing pipes to replace the one(?) you have now. I would assume the electronics on the car would be the same (Overboost, boost enrichment) so there would be little change to anything else.

Just my thoughts.

jeff

You need quite a few other parts, but it is not that hard. there were not that many intercooled 240s, but fortunately many of the 740 intercooler parts will fit even though they were different. Actually I would recommend using 740 intercooler parts if you can. They fit better then the originals, particularly if you put a B230 intake manifold on your car at the same time.