How to remove and reassemble the intercooler on Volvo S40?

To get started, remove the front bumper by removing the clips and removing the plastic bumper bar cover. Next, undo the upper screws holding the lower air baffle in place, keeping in mind that they are not the easiest screws to get at and may take some patience to undo. Then, loosen the clamps and unconnect the air pipes from the intercooler and finally, unbolt the bolts on both sides at the bottom of the intercooler. Slightly lift the intercooler so the hooks are disengaged and then lower the intercooler down, being sure to first undo the intercooler mounting bolts on each side. For the 2.4 litre models, disconnect the wiring plug for the manifold absolute pressure sensor before removing it. To reassemble, follow the reverse procedure of the disassembly process.

How to remove the intercooler components from the engine compartment on Volvo V40?

To remove the components, start by releasing the retaining clips and screws to remove the engine compartment front cover panels. Next, remove the EVAP purge valve from mountings and place it to side. Drain the cooling system and then loosen the hose clip to disconnect the air ducting from the base of the intercooler top hose at the radiator. Loosen the hose clips and remove the intake air ducts from the ports in the top of the intercooler. Unplug the wiring from the inlet air temperature sensor and the motors for the cooling fan and release the wiring from the clips on the back of the radiator assembly. From underneath the engine compartment, undo the hose clip to disconnect from the base of the intercooler the air ducting, and the bottom hose from the radiator. Unbolt the radiator upper mounting brackets from the bodywork, and pull the radiator, intercooler and cooling fans out of the engine compartment. Finally, undo the securing bolts and remove the intercooler and cooling fans from the radiator. For refitting, follow the reverse of the removal procedure.

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23 Intercoolers found

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Volvo Intercooler Part Number: 31657534
$58.94 MSRP: $87.84
You Save: $28.90 (33%)
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Product Specifications
- Other Name: Resonator; Intercooler
Fits the following Volvo Models:
- S60 | 2022
- V60 Cross Country | 2023 | B5 Plus, B5 Ultimate | 4 Cyl 2.0 L MILD HYBRID EV-GAS (MHEV)
- XC60 | 2022-2023
- XC90 | 2023 | B5 Core, B5 Plus | 4 Cyl 2.0 L MILD HYBRID EV-GAS (MHEV)
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Volvo Intercooler Part Number: 32324079
$58.94 MSRP: $87.84
You Save: $28.90 (33%)
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Product Specifications
- Other Name: Resonator; Intercooler
- Replaces: 31684281
Fits the following Volvo Models:
- XC40 | 2023 | B4 Plus, B4 Ultimate, B5 Core, B5 Plus, B5 Ultimate | 4 Cyl 2.0 L MILD HYBRID EV-GAS (MHEV)
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Volvo Intercooler Part Number: 8649471
$363.18 MSRP: $432.36
You Save: $69.18 (16%)
Ships in 1-2 Business Days
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Product Specifications
- Other Name: Charge Air Cooler; Turbocharger Intercooler; Intercooler
Fits the following Volvo Models:
- S60 | 2001-2002 | 2.4T, AWD, Base, T5 | 5 Cyl 2.3 L GAS, 5 Cyl 2.4 L GAS
- S80 | 1999-2003 | 2.9, T6 | 6 Cyl 2.8 L GAS, 6 Cyl 2.9 L GAS
- V70 | 2001-2002 | 2.4T, Base, T5, X/C | 5 Cyl 2.3 L GAS, 5 Cyl 2.4 L GAS
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Volvo Intercooler Part Number: 8683169
$359.06 MSRP: $427.46
You Save: $68.40 (16%)
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Product Specifications
- Other Name: Charge Air Cooler; Intercooler
Fits the following Volvo Models:
- S60 | 2003-2009 | 2.5T, 2.5T AWD, AWD, R | 5 Cyl 2.5 L GAS
- V70 | 2004-2007 | R | 5 Cyl 2.5 L GAS
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Volvo Cooler Part Number: 30730524
$533.98 MSRP: $689.89
You Save: $155.91 (23%)
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Product Specifications
- Other Name: Charge Air Cooler; Intercooler; Cooler
Fits the following Volvo Models:
- V70 | 2004-2007 | R | 5 Cyl 2.5 L GAS
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Volvo Intercooler Part Number: 9492730
$561.67 MSRP: $725.68
You Save: $164.01 (23%)
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Product Specifications
- Other Name: Charge Air Cooler 2603; Intercooler
Fits the following Volvo Models:
- 850 | 1993-1997 | Base, GLT, R, T-5, T-5R, Turbo | 5 Cyl 2.3 L GAS, 5 Cyl 2.4 L GAS
- C70 | 1998-2004 | Base | 5 Cyl 2.3 L GAS, 5 Cyl 2.4 L GAS
- S70 | 1998-2000 | AWD, Base, GLT, GLT SE, T5 | 5 Cyl 2.3 L GAS, 5 Cyl 2.4 L GAS
- V70 | 1998-2000 | AWD, Base, GLT, GLT SE, R, R AWD, T5, X/C AWD, X/C AWD SE | 5 Cyl 2.3 L GAS, 5 Cyl 2.4 L GAS
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Volvo Intercooler Part Number: 8671694
$481.19 MSRP: $729.07
You Save: $247.88 (34%)
Ships in 1-2 Business Days
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Product Specifications
- Other Name: Charge Air Cooler; Turbocharger Intercooler; Intercooler
Fits the following Volvo Models:
- S60 | 2003-2009 | 2.4, 2.4T, Base, T5 | 5 Cyl 2.3 L GAS, 5 Cyl 2.4 L GAS
- S80 | 2003-2006 | 2.5T, 2.5T AWD, 2.9, T6, T6 Premier | 5 Cyl 2.5 L GAS, 6 Cyl 2.9 L GAS
- V70 | 2003-2007 | 2.4, 2.4T, 2.5T, 2.5T AWD, Base, T5 | 5 Cyl 2.3 L GAS, 5 Cyl 2.4 L GAS, 5 Cyl 2.5 L GAS
- XC70 | 2003-2007 | Base, Ocean Race, X/C | 5 Cyl 2.5 L GAS
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Volvo Intercooler Part Number: 31319262
$509.96 MSRP: $772.67
You Save: $262.71 (34%)
Ships in 1-2 Business Days
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Product Specifications
- Other Name: Charge Air Cooler; Turbocharger Intercooler; Intercooler
Fits the following Volvo Models:
- C30 | 2008-2013 | T5, T5 R-Design | 5 Cyl 2.5 L GAS
- C70 | 2006-2013 | T5 | 5 Cyl 2.5 L GAS
- S40 | 2004-2011 | 2.4i, i, T5, T5 R-Design | 5 Cyl 2.4 L GAS, 5 Cyl 2.5 L GAS
- V50 | 2005-2011 | 2.4i, i, T5, T5 R-Design | 5 Cyl 2.4 L GAS, 5 Cyl 2.5 L GAS
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Volvo Intercooler Part Number: 31338306
$509.96 MSRP: $772.67
You Save: $262.71 (34%)
Ships in 1-2 Business Days
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Product Specifications
- Other Name: Charge Air Cooler; Intercooler
Fits the following Volvo Models:
- S60 | 2019-2021 | T5 Inscription, T5 Momentum, T5 R-Design, T6 Inscription, T6 Momentum, T6 R-Design, T8 Inscription, T8 Polestar, T8 R-Design, T8 Recharge Inscription, T8 Recharge Polestar, T8 Recharge R-Design, T8 Recharge R-Design Expression | 4 Cyl 2.0 L GAS, 4 Cyl 2.0 L PLUG-IN HYBRID EV-GAS (PHEV)
- S90 | 2017 | T5 Inscription, T5 Momentum, T6 Inscription, T6 Momentum | 4 Cyl 2.0 L GAS
- V60 | 2019-2021 | T5 Inscription, T5 Momentum, T5 R-Design, T6 Inscription, T6 Momentum, T6 R-Design, T8 Polestar, T8 Recharge Polestar | 4 Cyl 2.0 L GAS, 4 Cyl 2.0 L PLUG-IN HYBRID EV-GAS (PHEV)
- V60 Cross Country | 2020-2022 | T5 | 4 Cyl 2.0 L GAS
- V90 | 2018-2021 | T5 Inscription, T5 R-Design, T6 Inscription, T6 R-Design | 4 Cyl 2.0 L GAS
- V90 Cross Country | 2017-2021 | T5, T6, T6 Ocean Race | 4 Cyl 2.0 L GAS
- XC60 | 2018-2022 | T5 Inscription, T5 Momentum, T5 R-Design, T6 Inscription, T6 Momentum, T6 R-Design, T8 Inscription, T8 Momentum, T8 Polestar, T8 R-Design, T8 Recharge Inscription, T8 Recharge Inscription Expression, T8 Recharge Polestar, T8 Recharge R-Design | 4 Cyl 2.0 L GAS, 4 Cyl 2.0 L PLUG-IN HYBRID EV-GAS (PHEV)
- XC90 | 2016-2021 | T5 Inscription, T5 Momentum, T5 R-Design, T6 First Edition, T6 Inscription, T6 Momentum, T6 R-Design, T8 Excellence, T8 Inscription, T8 Momentum, T8 R-Design, T8 Recharge Inscription, T8 Recharge Inscription Expression, T8 Recharge R-Design | 4 Cyl 2.0 L GAS, 4 Cyl 2.0 L PLUG-IN HYBRID EV-GAS (PHEV)
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Volvo Intercooler Part Number: 31338473
$509.96 MSRP: $772.67
You Save: $262.71 (34%)
Ships in 1-2 Business Days
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Product Specifications
- Other Name: Charge Air Cooler; Intercooler
Fits the following Volvo Models:
- XC70 | 2016 | T5, T5 Platinum, T5 Premier | 5 Cyl 2.5 L GAS
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Volvo Intercooler Part Number: 31338474
$509.96 MSRP: $772.67
You Save: $262.71 (34%)
Ships in 1-2 Business Days
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Product Specifications
- Other Name: Charge Air Cooler; Turbocharger Intercooler; Intercooler
Fits the following Volvo Models:
- S80 | 2008-2015 | T6 | 6 Cyl 3.0 L GAS
- XC70 | 2009-2015 | T6 | 6 Cyl 3.0 L GAS
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Volvo Intercooler Part Number: 31338475
$509.96 MSRP: $772.67
You Save: $262.71 (34%)
Ships in 1-2 Business Days
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Product Specifications
- Other Name: Charge Air Cooler; Turbocharger Intercooler; Turbocharger; Intercooler
- Replaces: 30741669, 31273910
Fits the following Volvo Models:
- S60 | 2011-2016 | T5, T6, T6 R-Design | 5 Cyl 2.5 L GAS, 6 Cyl 3.0 L GAS
- V60 | 2015-2016 | T6 Polestar, T6 R-Design, T6 R-Design Platinum | 6 Cyl 3.0 L GAS
- XC60 | 2010-2016 | T6, T6 Ocean Race, T6 Platinum, T6 Premier, T6 R-Design, T6 R-Design Platinum | 6 Cyl 3.0 L GAS
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Volvo Intercooler Part Number: 31338476
$509.96 MSRP: $772.67
You Save: $262.71 (34%)
Ships in 1-2 Business Days
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Product Specifications
- Other Name: Charge Air Cooler; Turbocharger Intercooler; Intercooler
Fits the following Volvo Models:
- S60 | 2012-2016 | T5, T5 Inscription Platinum, T5 Inscription Premier, T5 Platinum, T5 Premier, T5 Premier Plus | 5 Cyl 2.5 L GAS
- S60 Cross Country | 2016 | T5 Platinum | 5 Cyl 2.5 L GAS
- V60 | 2015-2016 | T5, T5 Platinum, T5 Premier, T5 Premier Plus | 5 Cyl 2.5 L GAS
- V60 Cross Country | 2015-2016 | T5, T5 Platinum | 5 Cyl 2.5 L GAS
- XC60 | 2015-2016 | T5, T5 Platinum, T5 Premier | 5 Cyl 2.5 L GAS
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Volvo Intercooler Part Number: 31474506
$509.96 MSRP: $772.67
You Save: $262.71 (34%)
Ships in 1-2 Business Days
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Product Specifications
- Other Name: Charge Air Cooler; Intercooler
- Replaces: 31338236
Fits the following Volvo Models:
- S60 | 2015-2018 | Polestar, T5, T5 Dynamic, T5 Inscription, T5 Inscription Platinum, T5 Inscription Premier, T5 Platinum, T5 Premier, T5 Premier Plus, T5 R-Design Special Edition, T6, T6 Platinum, T6 Premier Plus, T6 R-Design Platinum | 4 Cyl 2.0 L GAS
- S60 Cross Country | 2017-2018 | T5 | 4 Cyl 2.0 L GAS
- S80 | 2015-2016 | T5, T5 Platinum | 4 Cyl 2.0 L GAS
- V60 | 2015-2018 | Polestar, T5, T5 Dynamic, T5 Platinum, T5 Premier, T5 Premier Plus, T6 R-Design, T6 R-Design Platinum | 4 Cyl 2.0 L GAS
- V60 Cross Country | 2017-2018 | T5, T5 Platinum | 4 Cyl 2.0 L GAS
- XC60 | 2015-2017 | T5, T5 Dynamic, T5 Inscription, T5 Platinum, T5 Premier, T6, T6 Dynamic, T6 Inscription, T6 Ocean Race, T6 Platinum, T6 Premier, T6 R-Design | 4 Cyl 2.0 L GAS
- XC70 | 2015-2016 | T5, T5 Platinum, T5 Premier | 4 Cyl 2.0 L GAS
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Volvo Intercooler Part Number: 31686408
$509.96 MSRP: $772.67
You Save: $262.71 (34%)
Ships in 1-2 Business Days
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Product Specifications
- Other Name: Charge Air Cooler; Intercooler
- Replaced by: 32249909
Fits the following Volvo Models:
- XC40 | 2019-2022 | T4 Inscription, T4 Momentum, T4 R-Design, T5 Inscription, T5 Momentum, T5 R-Design | 4 Cyl 2.0 L GAS
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Volvo Intercooler Part Number: 32249372
$509.96 MSRP: $772.67
You Save: $262.71 (34%)
Ships in 1-2 Business Days
ADD TO CART
Product Specifications
- Other Name: Charge Air Cooler; Intercooler
- Replaces: 31657812
Fits the following Volvo Models:
- S90 | 2022-2023 | B6 Inscription, B6 Momentum, B6 Plus, B6 R-Design, B6 Ultimate | 4 Cyl 2.0 L MILD HYBRID EV-GAS (MHEV)
- V90 Cross Country | 2022-2023 | B6, B6 Plus, B6 Ultimate | 4 Cyl 2.0 L MILD HYBRID EV-GAS (MHEV)
- XC60 | 2022-2023
- XC90 | 2023 | B6 Core, B6 Plus, B6 Ultimate | 4 Cyl 2.0 L MILD HYBRID EV-GAS (MHEV)
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Volvo Intercooler Part Number: 32249741
$509.96 MSRP: $772.67
You Save: $262.71 (34%)
Ships in 1-2 Business Days
ADD TO CART
Product Specifications
- Other Name: Charge Air Cooler; Intercooler
Fits the following Volvo Models:
- S60 | 2019-2023 | T5 Inscription, T5 Momentum, T5 R-Design, T6 Inscription, T6 Momentum, T6 R-Design, T8 Inscription, T8 Polestar, T8 R-Design, T8 Recharge Inscription, T8 Recharge Polestar, T8 Recharge R-Design, T8 Recharge R-Design Expression | 4 Cyl 2.0 L GAS, 4 Cyl 2.0 L PLUG-IN HYBRID EV-GAS (PHEV)
- V60 | 2023 | T8 Recharge Polestar | 4 Cyl 2.0 L PLUG-IN HYBRID EV-GAS (PHEV)
- XC60 | 2022-2023 | T8 Recharge Core, T8 Recharge Inscription, T8 Recharge Inscription Expression, T8 Recharge Plus, T8 Recharge Polestar, T8 Recharge R-Design, T8 Recharge Ultimate | 4 Cyl 2.0 L PLUG-IN HYBRID EV-GAS (PHEV)
- XC90 | 2016-2023 | T5 Inscription, T5 Momentum, T5 R-Design, T6 First Edition, T6 Inscription, T6 Momentum, T6 R-Design, T8 Excellence, T8 Inscription, T8 Momentum, T8 R-Design, T8 Recharge Core, T8 Recharge Inscription, T8 Recharge Inscription Expression, T8 Recharge Plus, T8 Recharge R-Design, T8 Recharge Ultimate | 4 Cyl 2.0 L GAS, 4 Cyl 2.0 L PLUG-IN HYBRID EV-GAS (PHEV)
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Volvo Intercooler Part Number: 32249933
$509.96 MSRP: $772.67
You Save: $262.71 (34%)
Ships in 1-2 Business Days
ADD TO CART
Product Specifications
- Other Name: Charge Air Cooler; Intercooler
- Replaces: 31439780
Fits the following Volvo Models:
- XC40 | 2019-2022 | T5 Inscription, T5 Momentum, T5 R-Design | 4 Cyl 2.0 L GAS
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Volvo Intercooler Part Number: 8627375
$509.96 MSRP: $772.67
You Save: $262.71 (34%)
Ships in 1-2 Business Days
ADD TO CART
Product Specifications
- Other Name: Charge Air Cooler; Turbocharger Intercooler; Intercooler
Fits the following Volvo Models:
- XC90 | 2003-2006 | 2.5T, Base, T6 | 5 Cyl 2.5 L GAS, 6 Cyl 2.9 L GAS
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Volvo Intercooler Part Number: 30630529
$599.58 MSRP: $725.88
You Save: $126.30 (18%)
Ships in 1-2 Business Days
ADD TO CART
Product Specifications
- Other Name: Charge Air Cooler; Intercooler
Fits the following Volvo Models:
- S40 | 2001-2004 | Base, LSE | 4 Cyl 1.9 L GAS
- V40 | 2001-2004 | Base, LSE | 4 Cyl 1.9 L GAS

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Volvo Intercooler Parts and Q&A

Intercooler
30889264
Q: How to remove and reassemble the intercooler on Volvo S40?
A:
To get started, remove the front bumper by removing the clips and removing the plastic bumper bar cover. Next, undo the upper screws holding the lower air baffle in place, keeping in mind that they are not the easiest screws to get at and may take some patience to undo. Then, loosen the clamps and unconnect the air pipes from the intercooler and finally, unbolt the bolts on both sides at the bottom of the intercooler. Slightly lift the intercooler so the hooks are disengaged and then lower the intercooler down, being sure to first undo the intercooler mounting bolts on each side. For the 2.4 litre models, disconnect the wiring plug for the manifold absolute pressure sensor before removing it. To reassemble, follow the reverse procedure of the disassembly process.
Intercooler
30630529
Q: How to remove the intercooler components from the engine compartment on Volvo V40?
A:
To remove the components, start by releasing the retaining clips and screws to remove the engine compartment front cover panels. Next, remove the EVAP purge valve from mountings and place it to side. Drain the cooling system and then loosen the hose clip to disconnect the air ducting from the base of the intercooler top hose at the radiator. Loosen the hose clips and remove the intake air ducts from the ports in the top of the intercooler. Unplug the wiring from the inlet air temperature sensor and the motors for the cooling fan and release the wiring from the clips on the back of the radiator assembly. From underneath the engine compartment, undo the hose clip to disconnect from the base of the intercooler the air ducting, and the bottom hose from the radiator. Unbolt the radiator upper mounting brackets from the bodywork, and pull the radiator, intercooler and cooling fans out of the engine compartment. Finally, undo the securing bolts and remove the intercooler and cooling fans from the radiator. For refitting, follow the reverse of the removal procedure.