Are you saying the original diesel intercooler was crap, or the gas one? I have been around on the volvo forums and didn't run across to many complaints about the stock intercoolers not being effective..
For hooking up the intercooler, you can clock the turbo housing a different direction and do a silicone 90 degree fitting on it to run to the intercooler. To go into the manifold, you can remove the boost dump valve and clamp a inlet pipe there. The stock inlet will have to be caped. I'm going to have a plate of a aluminum welded over the stock inlet. The easy way to do it would be to use a D24 NA manifold and plump your intercooler inlet to the stock inlet, its in the same location as the dump valve but much larger. I'm planning on cutting off the flange for the dump valve, boring out the opening, and having a small section of 2" or 2.5" (depending on what I come up with for an intercooler) welded to the front of the manifold. Pretty much duplicating the NA manifold.
Jason
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