How to remove and reassemble the intercooler on 2009 Volvo S40?

Start by taking off the front bumper and the plastic cover. Remove the upper screws (upper) of the lower air baffle, remove the air pipes from the intercooler. Remove the intercooler by lifting it up after unbolting it. For 2.4 litre models disconnect the manifold relative pressure sensor.

Genuine 2009 Volvo S40 Intercooler

Front Intercooler

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2009 Volvo S40 Intercooler Part Number: 31319262
$509.96 MSRP: $772.67
You Save: $262.71 (34%)
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Product Specifications
- Other Name: Charge Air Cooler; Turbocharger Intercooler; Intercooler
- Condition: New
- Fitment Type: Direct Replacement
- SKU: 31319262
- Warranty: This genuine part is guaranteed by Volvo's factory warranty.
Fits the following 2009 Volvo S40 Submodels:
- 2.4i, i, T5, T5 R-Design | 5 Cyl 2.4 L GAS, 5 Cyl 2.5 L GAS

2009 Volvo S40 Intercooler Parts and Q&A

Q: How to remove and reassemble the intercooler on 2009 Volvo S40?
A: Start by taking off the front bumper and the plastic cover. Remove the upper screws (upper) of the lower air baffle, remove the air pipes from the intercooler. Remove the intercooler by lifting it up after unbolting it. For 2.4 litre models disconnect the manifold relative pressure sensor.