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Pelican Technical Article:

Intercooler Removal

Jared Fenton

Time:

3 hours3 hrs

Tab:

$0 to $200

Talent:

****

Tools:

T30 Torx driver, flat head screwdriver, pressure washer

Applicable Models:

Volvo C30 T5 (2008-13)
Volvo C30 T5 R-Design (2008-13)

Parts Required:

Intercooler

Hot Tip:

Pressure wash the fins of the intercooler before re-installing it

Performance Gain:

More surface area to cool intake boost means more power

Complementary Modification:

Replace intercooler hoses

Turbocharged engines such as the T5 in the Volvo C30 rely on a device called an intercooler to cool down the intake air. The intake air coming from the turbocharger is hot. Cooling it down allows the air to become more dense, which in turn allows the engine to make more power.

Various projects on the Volvo C30 require you to remove the intercooler for access to the radiator as well as some of the air conditioning components. At the same time, it is beneficial to take the time to clean the parts of the intercooler that are constantly exposed to on-coming air. This can leave a layer of dirt or debris that can impede cooling. I typically use a pressure washer to blast out the small fins on the inside and restore air flow when the car is moving. Don't clean out the inside unless you find a bunch of oil. In this case, you have a bigger problem. See our article on Turbo Replacement for more information. Keep in mind that you want to use a low setting if using a pressure washer. Additionally, you can also just use a spray nozzle with a garden hose.

Shown here is the intercooler on your Volvo C30 with the front bumper cover removed.
Figure 1

Shown here is the intercooler on your Volvo C30 with the front bumper cover removed.

Move to the right side of the car and locate the boost pressure sensor on the top of the intercooler.
Figure 2

Move to the right side of the car and locate the boost pressure sensor on the top of the intercooler. Press the tab on the electrical connector (green arrow) and pull it off the sensor.

Loosen the hose clamp (green arrow) on the left side of the intercooler.
Figure 3

Loosen the hose clamp (green arrow) on the left side of the intercooler.

Pull the intercooler hose leading to the throttle body off the intercooler.
Figure 4

Pull the intercooler hose leading to the throttle body off the intercooler.

Loosen the hose clamp (green arrow) on the right side of the intercooler and pull the hose off.
Figure 5

Loosen the hose clamp (green arrow) on the right side of the intercooler and pull the hose off.

You'll need to release the intercooler air baffle from the radiator support frame.
Figure 6

You'll need to release the intercooler air baffle from the radiator support frame. Press the tabs (green arrows) and pull the air baffle (yellow arrow) straight out.

Loosen and remove the T30 Torx screw (green arrow) holding the left side of the intercooler to the radiator support frame.
Figure 7

Loosen and remove the T30 Torx screw (green arrow) holding the left side of the intercooler to the radiator support frame. You may need to move the air baffle around a bit to access this screw.

Loosen and remove the T30 Torx screw (green arrow) holding the right side of the intercooler to the radiator support frame.
Figure 8

Loosen and remove the T30 Torx screw (green arrow) holding the right side of the intercooler to the radiator support frame.

Now fold the air baffle up to clear the intercooler.
Figure 9

Now fold the air baffle up to clear the intercooler. You may need a helper to hold this up. Lift the intercooler up slightly so that the guide pin (green arrow) slides out of the receiver (yellow arrow) on the support frame. You can now pull the intercooler off the car.

And shown here is the final result with the intercooler removed.
Figure 10

And shown here is the final result with the intercooler removed. Installing the intercooler is the reverse of removal.



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Page last updated: Wed 12/7/2016 02:39:09 AM