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Doug,
What I did on my '82 242, was to grab the complete intercooler kit off a 1984.5 245Ti that had been run out of oil. Or, try to. Two of the hoses were missing, so, since I was planning to do the B230 intake on our '83 245Ti, I grabbed the good hoses from that car and slapped them onto my 242 (also wound up grabbing the turbo from the '83 - we'll save that story for another time). Took me 2.5 hours or so to do the intercooler install. But, it's been working fine ever since I did the install. Wish I could say the same about the helicoil job I did on the head. Drill went in at an angle on the lower #4 exhaust stud hole. Needless to say, I've got a head swap in my not-so-distant future. Have a later model B21FT head (from another '84.5 245Ti) that I will send in for rebuilding, and then, will swap it on, and have an exhaust leak free 242Ti.
-J
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1972 142E B20F/M40 - 410K km; 1973 164E B30F/M410 - 238K km; 1974 145E B20F/M41 - 600K km; 1982 242Ti B21FT/M46 - 388K km; 1983 245Ti B21FT/AW71 - 264K km; 1985 245GL B230E-LH/M46 - 420K km; 1987 744Ti B230FT/AW71 - 270K km
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