Volvo 240 Cooling Stack
Cooling System Upgrades for the Volvo 240
Donut Media coined the phrase “Cars are pain,” and honestly, it’s pretty relevant to this situation. What should have been a straightforward task turned into a classic example of nothing ever being truly bolt-on. So, we’re here to share our process in the hopes that it might help someone else attempting the same conversion.
Choosing the Right Cooling Components
You’d think that sticking with a red block in a Volvo 240 would make finding off-the-shelf radiator upgrades and intercoolers a breeze. And to some extent, that’s true, there are well-regarded options available. After researching what was on the market, we opted for a larger, factory-style radiator, commonly available through Volvo parts suppliers, as well as an upgraded intercooler designed for the 240 Turbo.
The radiator appeared to match the stock unit’s dimensions but with added thickness to improve cooling capacity, which suited our build.
Fitting the Cooling Stack
Once the parts arrived, we set about installing them, but it quickly became apparent that the radiator and intercooler sat significantly higher than the factory core support. We explored possible solutions, including lowering the mounting position, but modifying the lower radiator support wasn’t an option.
The stock radiator sits on a crossmember that forms part of a two-piece structure, which ties the front of the car together. Altering this could compromise crash safety, and New Zealand’s regulations on structural modifications are strict, making changes here could have rendered the vehicle unregisterable.
It became clear that factory turbo models may have had a different core support or mounting provisions, allowing for a lower fitment. In our case, the positioning forced the radiator and intercooler to sit higher than expected.
Creating a Mounting Solution
To test clearance, we temporarily secured the radiator and intercooler with cable ties and checked bonnet fitment. Surprisingly, everything fit without interference, with enough space for proper airflow. This meant we could move forward with designing a secure mounting solution.
For the lower mounting points, we added a length of aluminium angle behind the radiator support, secured with M10 bolts. This provided a stable base for the radiator while maintaining the structural integrity of the car. To prevent wear, we applied EVA foam padding between the radiator and aluminium bracket, reducing vibration and potential chafing.
For the intercooler, we modified the stock radiator mounts to accommodate the increased width. Once in place, it sat around 30mm above the radiator support, aligning neatly with the radiator itself.
Finalizing the Upper Mounts
Since the radiator and intercooler needed to be mounted at an angle for bonnet clearance, we designed a 30-degree angled spacer in CAD and 3D printed it using carbon fiber nylon. This material provided both strength and a protective barrier between the stainless bolts and aluminium bracket, preventing galvanic corrosion.
The brackets were shaped with a 90-degree fold at the back and a 30-degree fold at the front, securing the radiator and intercooler from movement in any direction. Given that the radiator will be heavy when filled with coolant, and that under acceleration it would naturally shift toward the engine, these mounts needed to withstand significant forces.
We also ensured that the stock radiator fan shroud could still be used for optimal airflow. Fortunately, the upgraded radiator had factory-style mounting points, allowing direct installation. Due to the increased thickness of the cooling stack, we trimmed the shroud to fit, resulting in a clean, functional setup.
Final Upgrades
Oil Cooling on this car the oil filter mounts to a original Volvo thermostat, which we’ve adapted for -10AN fittings, allowing easy integration of an oil cooler we went with a quality Setrab cooler with 200 series speedflow hose and fittings.
To complete the look, we used Black Cerakote on the aluminium brackets for a more factory-like finish.
Our final touch was to add our machinery tag with all the important engine specs noted. This was inspired by our history working on large marine engines.
Closing Thoughts
Although the radiator and intercooler required additional work to fit correctly, the final result is a strong, well-integrated cooling system. The extra effort spent refining the setup has resulted in a solution that feels purpose-built for our application and not a single cut was made to the front of the car which will keep the New Zealand authorities off our back.
While no aftermarket part is ever truly a drop-in replacement, this process reinforced the importance of understanding fitment challenges before installation and adapting as needed. If you’re considering a similar setup, hopefully, this guide helps make the process smoother!
