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