2004-2007 Volvo S60R V70R front mount intercooler

I have been working on this intercooler for months making sure it is as perfect as it can get. In my opinion it is the only true front mount available for these cars.

It is the only intercooler that is not blocked by the crash bar, it’s not mounted between the AC condenser and the radiator (like stock), and is fully in the opening of the bumper.

This replaces both the stock intercooler between the rad and AC con, as well as the small one in the bumper.

This can be used with the stock charge pipes. Select stock to be used with the stock pipe, or select 2.5” to be used with my cold pipe.

Core size is 22”x6”x3.5” with 2.25” inlet and 2.25” outlet, or 2.5” for aftermarket.

Core is good to 550hp (crank), so this intercooler is good up to a large hybird turbo.

The black coating in the pics is not a powder coat. It is a Thermal Dispersant Coating that is known to rapidly cool aluminum in direct airflow.

INSTALL NOTES.

On the V70R’s there is no need to remove the crash bar. On SR’s I recommend removing the crash bar by drilling out the 4 spot welds that hold it to the chassis. There’s 2 on each side. You do not have to modify the crash bar. It does help to loosen the radiator as it may need to be moved back some. I supply all the hardware needed for install. There are nylon spacers that come with the kit that go between the radiator and the AC con, as well as the intercooler and the AC con. Only use the spacers that go between the intercooler and the AC con on the VR models. You do not have to modify the crash bar on either model.

You have to cut the bottom of the bumper cover on both the SR and VR. Mark a line parallel on the bottom of the bumper 1 inch inward. I use a razor blade heated up with a torch, once the blade is hot, it cuts the plastic very easily. You can also use a pair of tin snips to cut the plastic.

Video for the install on a VR can be found here. Its similar for the SR models other than the comments above.

https://youtu.be/qI0EKBnVY3A