We're almost done installing an intercooler on a 1981 242 Turbo. The only part of the job that doesn't fit really well is the nipple on the passenger upper corner of the radiator. This nipple takes the small hose from the expansion tank. The nipple ends up really tight against the short intake intercooler hose that's between the passenger-side hardpipe and the intercooler. Even with the nipple bent a little bit upward, it's still a really tight fit to even get the little hose on it. I can't imagine Volvo designing it this way on the later intercooled cars. The radiator needs replacing soon, and I'm wondering if there's one available that has this nipple positioned differently to allow more clearance. Or maybe someone has an idea that has worked for them. I looked up the Nissen radiators that FCP sells and it says the same one fits all four cylinder 240's. Did they reposition this nipple to allow clearance on the intercooled cars? Any ideas?
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Thanks everyone for all the help, Doug C. 81 242 Brick Off Blocks, turbo bars and wheels, M46; 86 244, B230, 150k , auto.