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Front Mount Intercooler: The Write Up


Oreo931

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Many thanks!

A few questions...

Do you still feel that it was a significant improvement, and did you get any dyno #'s or track times since last Aug?

Did you get your pipes welded or are you still using the multiple connectors?

Did you figure out a way to reinstall the fogs or did you just leave 'em off?

In the alabama heat, I definately have noticed a difference in less lag most of all. I can only assume the intake temps are lower as well but down here, it averages at LEAST 98* in the summer (which is around 9 months out of the year) so for me, yes I feel it was a worthy investment and eventually plan on doing the same with the wife's car, though for all the trouble and headaches I ran into with mine, I'd probably spend a bit more on a drop in replacement simply because I battled with boost leaks, pipes coming off at WOT, etc and I don't want my wife stranded on the side of the road with an intercooler pipe joint separated.

I think that the FMIC though, if you're willing to put up with more head scratching and a bit more time under the hood, will offer better cooling and performance gains than the typical drop in IC.

I never got to do a before/after dyno or track run so real world performance numbers are absent. I was at the track for the south east volvo meet the day after I installed it and while at the time it was leaking all sorts of boost and blowing the hose off the throttle body at every WOT 3rd gear shift, it went 15.0 @ maybe the mid 90's. I can't remember.

I never got around to getting the pipes welded. Sam got a new job and doesn't work at the dyno shop we used that day any more. They've held 15~17 psi for almost a year now with no problems though. If you get a bead welded to the edge of all the pipes where you cut them and use tight Tbolt clamps, blowing pipes off or leaking boost from the joints shouldn't really be an issue. Me not getting those beads welded on was my #1 mistake.

For the fogs, I COULD have gotten to keep them if I had paid more attention to where I made the pipe cuts there on those J bends coming out of the intercooler and going back around up to the engine. If I had shortened the area that comes out of the IC, they would have fit. I just totally forgot about that during the install. It wasn't all that bad though because my wife's T5 didn't have fog lights so I put them in her car and used the solid bumper fog light hole covers in my bumper to hide the piping.

So it went from this

IMG_8294.jpg

To this (I know the IC is leaning in that pic.. it's been fixed) I had to go from regular nut/bolt to the plastic teflon coated self locking nut on the bolts that hold the IC up. (which I don't have any pics of btw)

IMG_8742.jpg

Thanks :D.

Unfortunately, I do not think it will be pinned or added to Bay13 :(.

+1

I believe my Axle install and exhaust install will also never see the light of day in bay 13... shame really. ;)

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I think that the FMIC though, if you're willing to put up with more head scratching and a bit more time under the hood, will offer better cooling and performance gains than the typical drop in IC..

Thanks!

I'm going to have to seriously consider this. First, I think I'm gonna go for an 18T, though. Just trying to locate one for a good (cheap) price!

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  • 11 months later...

looks great! I'll be doing this within the month. yay

Question about your BOV..thats an RFL right?

Our cars do or dont have reciriulating BOV's? The reason I ask is because I'm from the DSM world and thats a must have. I'd be excited to hear that it can blow free.

Thanks

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Adam thanks so much for helping Chris and me out yesterday!! We really appreciated it...but we used less piping than you :P .

Our hot side piping was basically the same as yours. But on the cold side where you come out of the ic with a reducer->180 bend->90 coupler....we came straight out of the ic with the stock upper ic coupler ( the 90 degree that goes from the ic to the upper ic pipe). Then put the other 45 degree bent pipe and straight into my bov coupler into a cut upper ic pipe...it looks awesome, leaves a lot of space for an intake pipe and reduced about 2 feet of your piping :D . I'll get some pics up soon.

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  • 8 months later...

Probably bringing this up from the dead..I am doing this as we speak and I ordered 2.25 piping but got 2.50 instead, should I try to run it, or see if the company will take it back?

Unfortunately I tried to run a big intercooler(got it for free from a buddy) Got it mounted where I thought it would work, but will not work where I had it. So I cut up my bumper to get it to fit for nothing, and will be ordering a smaller intercooler tonight..Here is a "in progress" Picture for you guys anyways.

IMG00072-20100510-0643.jpg

BTW.. Name is jason, am 19 years old and this is my first volvo project. by far not my first car project though. So far the volvo has kept it interesting. Before I bought it I completely underestimated its power.

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follow the guidelines that the rest of us who have successfully completed this project have followed and it will work. There are very few corners you can cut. If you get what we got and install how we installed, it'll be a fairly trouble free install.

2.5" piping is going to be an epic pain in the ass routing down by the alternator. Just use 2.25"

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Adam thanks so much for helping Chris and me out yesterday!! We really appreciated it...but we used less piping than you :P .

Our hot side piping was basically the same as yours. But on the cold side where you come out of the intercooler with a reducer->180 bend->90 coupler....we came straight out of the intercooler with the stock upper intercooler coupler ( the 90 degree that goes from the intercooler to the upper intercooler pipe). Then put the other 45 degree bent pipe and straight into my bov coupler into a cut upper intercooler pipe...it looks awesome, leaves a lot of space for an intake pipe and reduced about 2 feet of your piping :D . I'll get some pics up soon.

Thanks! I just did this today and not Only did I cut a couple feet of pipe, but I also got my stock intake piping back in. I had to take it out with the way I had the FMIC piping routed before.

Thanks Jason for resurrecting this topic, lol. Probably would've never seen it. I basically did what Drew suggested and followed what other guys have done with the size of the intercooler and 2.25" piping, just to make it easier on myself.

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I fit 2.5 straight down the passenger side of the fan shroud. A few things had to be hacked off but if you have seen my bumper thread you know that it wasn't really an issue for me.

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well I thought spending the extra money ($280 for piping/couples/clamps alone) Would get me a reputable company. But they won't take the piping back since it was "custom bent" looks like I may have no choice but to try and use 2.5"...just doing some test fitting already has me uneasy about this project. The new intercooler should be here by the weekend, if thats the case I will tackle this on saturday, as I would like to run it at the local track saturday night too see what times it puts down as opposed to stock. Also added an intake today, by far the best mod for the money, holds boost much stronger now. here is my (lame) car domain page if anyone wants to keep up on my progress. i'm sure I will be back this weekend with lots of questions..or maybe just to vent about how much this car hates me..seems to fight me every step of the way with mods.

woops. forgot to add the CD link.

http://www2.cardomain.com/ride/3854730

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