Another Blown Intercooler
 

It was only a matter of time, but at 71,000 miles I'm a bit surprised that the intercooler has blown already. Must be my heavy right foot :) You may be aware that the new Google search format on mobile phones it poor compared to what it used to be, so I'm having difficulty retrieving specific threads on here. Somewhere in the depths of this forum is a thread highlighting an adequate aftermarket intercooler replacement. My car is a 2004 S60 D5 163bhp, and has the boost sensor located just above the pipe on the passenger side of the intercooler.

Has anybody replaced the intercooler with an aftermarket unit, and if so what intercooler did you use? I hear good things about the Nissens 969001, but would like to hear other peoples thoughts before pulling the trigger on one.

Thanks in advance chaps

Me too. I'm at 157 and .............well nothing. Could it be overboosting ?

Just throwing Dice onto it now. Will report back with any fault codes

This to be going on with some pics near the end of the thread.
http://www.volvoforums.org.uk/showthread.php?t=226658

Post #7 in this one has some info about Nissens
http://www.volvoforums.org.uk/showth...ns+intercooler

Only fault code is ECM-6805 Boost Pressure Control - Faulty Flow

Seems it could be a number of things. TCV, engine mounts, intake/intercooler hoses or the intercooler itself. Seeing as how the intercooler is obviously leaking and looks like a banana, that's where my money is at. I will however try to test the mounts and valve/solenoid to eliminate them from my enquiries. Cheers Brendan

Mike's sticky would be a good place to start
http://www.volvoforums.org.uk/showthread.php?t=132443

Hope you do a better job fitting it than me. I almost poured petrol on my S60 and torched it.

Haven't got time or space to fit it, so a local Volvo indy is going to do the work. If space and time were available I'd have a blast at fitting it no problem.

They are just weak. Nissens do a good one will last 2 years min.

jack it high and level.
bumper off.
drain rad with big low hose. ~Keep the rad coolant. Take big rad hoses off leave top thin hose on.
wire off IC sensor
zip tie the aircon rad it situ
Holding the IC and RAD, pull the long bolts so only the RAD can be lowered. Rotate the Rad and stand it vertically on floor.
Pull the bolts another inch to drop/remove the IC below the car.

This way u dont need to remove the Aircon rad and No regas.

I'm convinced crappy egr debris clogs the right side of the i/c causing back pressure when on boost.
I may be wrong but they never seem to bow on the left.....
I think a clean egr is key to a free flowing non blowing intercooler.