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240 Oil Cooler Page

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Volvo Red Block OIL COOLER Information
This information may come in handy when working on or modifying oil cooler systems on 240s or other red block Volvos. 

Here's a factory Volvo (Wahler) oil cooler thermostat housing for a 240 Turbo. It is mounted between the engine and the oil filter.
This housing has banjo fittings on the cooler IN/OUT ports. This was common for the B21FT.  In later B230FT housings, the banjo fittings were eliminated and straight fittings were threaded into the housing.

The oil flow direction became something I needed to know when I wanted to install an in-line oil cooler thermostat between the engine and oil cooler. My original thermostat was not working well. It seemed to be partially stuck in the open position, so it was not allowing the oil to warm up quickly, taking many miles of highway driving to reach 180 degrees. The new in-line thermostat I chose to add required a specific flow direction for "in" and "out" ports. 

Here is the flow direction for this factory Wahler B21FT thermostat. 

This diagram below was found in the 1981 Volvo "New Car Features" Greenbook.

The factory 240 Turbo oil cooler, manufactured by Setrab in Sweden, was mounted vertically on the left side of the 240 radiator. This is not the best location for airflow, but it's certainly better than no oil cooler.

Significant airflow and cooling improvement can be made by relocating this cooler below the car, behind the front spoiler. It can be mounted there horizontally. It can be mounted 90 degrees to the ground like the below image or you can angle it some if you want more ground clearance. I had this oil cooler mounted like this for several years before I decided to upgrade to a larger Mazda RX7 oil cooler (details below).

Here are more flow direction images for the early and later (after 1986) B230FT oil cooler thermostat.  Oil always flows into the oil filter around the OUTSIDE edges and then it flows out of the filter, back into the engine through the CENTER of the filter.
Here are some more images of these oil pipes. 
NOTE: Early (B21FT) original Volvo pipes used banjo fittings at the oil filter/thermostat plate and later (B230FT) pipes used straight fittings threaded into the plate.

And some detail images of the later (after 1986) B230FT setups.

Again, the Volvo 240 Turbo Wahler oil filter/thermostat plate using banjo fittings. The large threaded pipe in the center of the plate uses 3/4 -16 thread.  It's a common thread size for many factory and aftermarket oil filter adapters that may be found for a large number of cars, typically Ford, Lincoln and Mercury. The IN/OUT cooler ports on this plate are threaded 16mm x 1.5 Female.

 If you're relocating your Volvo Setrab oil cooler or converting your old oil cooler pipes to racing style AN fittings and hose, you can still use the above Volvo Wahler oil filter/thermostat sandwich plate. The ports on that plate are threaded 16mm x 1.5 Female.  If you will be using -8 AN racing hose, you'll need two 16mm x 1.5 Male to -8 AN Male Adapters (same as THIS photo), which can be found at https://www.summitracing.com/parts/rus-670551.
To seal the cooler side, you'll need two 16mm aluminum crush washers or bonded sealing washers. Metric aluminum crush washers are available at Pegasus Racing: https://www.pegasusautoracing.com/productselection.asp?Product=3278

<<< This is a metal-bonded sealing washer.  It's a metal washer with a rubber o-ring embedded in it.  It's generally used in place of a brass or aluminum crush washer, except it has superior sealing. McMaster Carr has them: https://www.mcmaster.com/#standard-washers/=1blhle3, click "Sealing Washers," then "Metric High-Pressure Metal-Bonded Sealing Washers" and choose size M16.   They can also be found at Pegasus Racing, called Stat-O-Seal Sealing Washers: https://www.pegasusautoracing.com/productselection.asp?Product=3245. Choose the 5/8 inch size, which has an ID of 15.9 mm.  Your local hydraulic hose shop may have them too.

You can see other bonded washers I used further below CLICK HERE.

 <<< The male ports on a stock Volvo Setrab oil cooler used in 240 Turbo and 740 Turbo models shown here are size: 1/2 BSP Male

<<< If you'll be using -8 AN racing hose, you'll need two adapters with the following thread: 1/2 BSP Female to -8 AN Male, available at https://www.pegasusautoracing.com/productselection.asp?Product=3252.  

Thread Info Reference: https://forums.turbobricks.com/showpost.php?p=4841878&postcount=7

The factory 240 Turbo oil hoses were made to be pretty durable. They were hard steel tubes coupled to flexible reinforced rubber hoses on the ends that connected to the oil cooler.  Relocating the oil cooler will make it difficult to use the factory lines. There are a lot of simple universal kits and parts that can be used on a 240 for a remote filter and/or oil cooler.  I have used universal kits in the past with simple 1/2 inch I.D. oil hose, which will usually come with most the universal kits. These kits will use brass barbed nipple fittings and worm-drive hose clamps. They work fine, but I should warn you that inexpensive rubber oil hose does tend to harden and shrink over years of heat exposure. This can cause your tight hose clamp connections to slowly loosen and then begin leaking.  So it's a very good idea to check those on occasion.
Here are a few example kits that will fit a 240:

If you're shopping for a new aftermarket filter adapter or thermostatic plate and need to know if it fits a Volvo oil filter, you may need to know the diameter of the stock Volvo oil filter o-ringIt's 2.75 inches. If you find an adapter that's at least 2.5 inches, it should fit also. 

There are lots of custom parts and universal kits on-line. For kits that supposedly fit a 240 directly, it's hard to know what you can trust and how well these parts will fit.  Here's such a kit with the thermostat plate, oil cooler and assembled oil hoses that was installed by a Volvo 240 Turbo owner and it seems to work nicely.
Thread: https://forums.turbobricks.com/showthread.php?t=344235

The large Mazda RX7 oil cooler (second generation RX7, FC, 1986-92) is a popular retrofit for a Volvo because of it's large size.  It has a built in thermostat that begins opening at 140 F and is fully open at 149 F. Those temps are too low for a Volvo, so using a thermostat elsewhere would be a better idea. The built-in thermostat is inside the end-tank where the IN-OUT ports are. It can be removed if you like and the bypass port inside can be blocked with a simple nut and bolt.
The IN-OUT ports on this oil cooler are threaded
18mm x 1.5 Female.  They originally used banjo fittings with brass crush washers, which you can also use if you like. An appropriate banjo fitting for this will use a center bolt with thread of 18mm x 1.5.  If you instead decide to install straight AN racing hose fittings, an appropriate straight adapter fitting will have the following thread: 18mm x 1.5 Male to -8 AN Male.  Appropriate 18mm crush washers or bonded sealing washers should be used on these ports whether you are using AN adapters or banjo fittings.


Here are some of the oil related ports on a Volvo red block.
B21/23FT: Turbo Oil Feed: M14x1.5.
B230FT:  Turbo Oil Feed: M14x1.5.
All engines: Oil Filter Center Port: 3/4-16.
B21/23FT: Oil Pressure Sender: 1/8 NPT.
B230FT: Oil Pressure Sender: M14x1.5.

Oil Cooler Thermostats
The factory Volvo (Wahler) oil cooler thermostat in my 240 Turbo seemed to stop working as it should.  My guess is it was stuck in the open position, since it was taking forever for the engine oil to come up to temperature.  So a number of years ago I decided to add an IN-LINE oil cooler thermostat. At that time I was using aftermarket 1/2 inch I.D. rubber oil hoses for the oil cooler lines. 
This is the Hayden 163 thermostat.
It's made of aluminum and designed for use with engine oil or transmission fluid. When cold it bypasses the cooler, returning oil to the engine. It begins releasing oil to the cooler at 160F and allows full flow at 180F.
Fittings/Threads included: 3/8 inch NPT with 3/8 inch and 1/2 inch barbed nipples so you can choose hose size.

Here are the instructions and an explanation of how it works.
https://www.davebarton.com/pdf/Hayden163.pdf (PDF 100kb)

This thermostat has 3/8 inch NPT Female threaded ports.  I used one of these for a while along with 1/2 inch I.D. rubber oil hoses clamped to barbed fittings.  A better solution (that I eventually changed to) is racing style AN fittings and high-performance oil hose, however it's more expensive. The adapters needed to use -8 AN oil hose on this thermostat would be 3/8 inch NPT male to -8 AN Male. Summit has some of these for as low as $3.00 each: https://www.summitracing.com/parts/sum-220846b.

In 2019 I decided to do a complete change with all new parts for my remote oil filter and RX7 oil cooler plumbing.  I was previously using cheap oil hose that I bought years earlier from Summit Racing.  It had served well, but after years of heat it had begun shrinking and hardening and the hose clamps were slowly loosening and causing leaks.  I could have just replaced it with new cheap oil hose from Summit, but instead I decided to upgrade to Aeroquip Socketless hose and then document the full installation here.

 My suggestion if you can afford it is
Aeroquip Socketless Hose (pictured below). This premium hose has a rubber core and it connects to special barbed Aeroquip Socketless hose fittings. Assembly is much faster and easier than other racing hose fittings. And routing hoses is easy because these hoses are more flexible than most other racing hose with stainless steel braided covering. Aeroquip Socketless is rated at 300 degrees Fahrenheit. More general info can be found here: https://www.jegs.com/p/Aeroquip/Aeroquip-Socketless-Racing-Hoses/750321/10002/-1

While no clamps are technically required for Aeroquip Socketless hose, a smart practice is to add simple Oetiker Clamps or Pinch Clamps. This will offer a stronger connection and seal, just in case.  These clamps may be found at Summit Racing, Grainger or other parts suppliers.

Here are some videos showing the installation of Oetiker clamps:

I needed to replace the factory
Volvo Wahler sandwich plate with an aftermarket adapter. Plus I decided that I would install a remote oil filter under the front right corner of the car.
The long factory threaded nipple needed to be removed.  It's threaded into the block and if it's never been removed, it will be tight. 
A pipe wrench will give you the grip and leverage you need.


This oil filter adapter is Derale Cooling Products PN 35703 from Summit Racing: https://www.summitracing.com/parts/der-35703.
The threads in the ports are AN -10 (O-ring). The "O-ring" means that an there is a recess machined into the ports (seen below) for an o-ring to be used under each of those hose fittings.
The hose fittings are Aeroquip FBM5163 (AN -10 male to -8 male adapters) and may be found here: https://www.summitracing.com/parts/aer-fbm5163. These hose fitting are considered to be reducer fittings. I used them because I prefer to use smaller AN -8 oil hose for a Volvo engine. AN -8 has an I.D. of 1/2 inch, instead of larger -10 hose (5/8 inch I.D.).

AN racing style hose internal diameter (ID) is measured in 1/16th of an inch increments.
-8 AN is 8/16th inch ID (1/2 inch).  -10 AN is 10/16th inch ID (5/8 inch).
It's that simple.
So I'm using -8 AN hose with this project, which is 1/2 inch I.D.

The long threaded factory Volvo nipple I removed is Volvo PN 1306707.
A new
, shorter threaded nipple was needed because I was removing the thick Volvo Wahler adapter plate. This caused a bit of a headache, because the only shorter nipple I had on hand was the 1 inch long nipple shown in the below photo. 1 inch was too short to get good thread engagement.

A factory Volvo short nipple,
Volvo PN 418440, is 1 5/8 inches long. It was used in all Volvo 240/740 models without an oil cooler adapter plate. I don't know if it's still available. This is the same nipple used for all red blocks beginning with the B18 in 1961.
I couldn't find a nipple in that length. Nearly every 3/4-16 nipple available on-line was either 1 inch or 1.25 inch long. So I ordered a 1.25 inch nipple and I waited.  To my surprise, it worked just fine. I was able to get 5 turns of thread engagement. The proper fitting 3/4-16 x 1.25 inch nipple was found here: https://www.summitracing.com/parts/trd-1034.

Aeroquip FBM5163 AN -10 male to -8 male adapter fittings shown, found here: https://www.summitracing.com/parts/aer-fbm5163.

That is heat shrink tubing below.  I'
ve had some things vibrate loose before, so I added that as a cheap safety measure.

A lower profile (and more expensive) alternative from Improved Racing Products is also available: https://www.summitracing.com/parts/irp-env-160.

Permatex thread sealant with Teflon (PTFE) was used for all threaded adapters.  This is essentially what people refer to when using "liquid Teflon tape."

While routing the hoses toward the front, there may be places where they come close or actually touch parts of the car. If you have a way to clamp them to the frame, that would be a good solution.  Otherwise some rubber or foam insulating material
, like this rubber sheeting, can be used to protect the hoses from chaffing.

Here's my RX7 oil cooler.  It's mounted under my car behind the front spoiler openings.
That's the IN port on top. These IN and OUT ports are threaded M18 x 1.5. Mazda normally used BANJO fittings with brass crush washers on these ports.
 For that top IN port I could have used an 18 mm x 1.5 to -8 AN Male Adapter and then a 180 degree AN hose fitting, but space was limited above this cooler.  So I found the shown aluminum BANJO fitting (
M8 x 1.5) in my parts bin and decided to make it work.  It's bolted to the port using an M18 x 1.5 banjo bolt.  Then I added a -8 AN Male to 3/8 inch NPT Adapter to the banjo fitting: https://www.summitracing.com/parts/aer-fbm5007 and then the -8 AN 90 degree Aeroquip Socketless hose end: https://www.summitracing.com/parts/aer-fbl1533.

Normally this oil cooler will use a BANJO fitting with brass or aluminum crush washers on both sides. I used some metal-bonded sealing washers instead.  
e's one of the metal-bonded sealing washers below along with the fitting I used in the bottom OUT port. It's Russell PN 670561, 18 mm x 1.5 to -8 AN Male: https://www.summitracing.com/parts/rus-670561.

I bought this set of metal-bonded sealing washers: https://www.amazon.com/gp/product/B07CKVYWD4/

Here's the RX7 oil cooler installed.

Here are the remote filter parts that were mounted under the front right front corner of the car, behind the bumper.

The oil filter mount has the body mount bracket. It's Permacool PN 1791: https://www.summitracing.com/parts/prm-1791.
This fits a normal Volvo oil filter or any similar filter using 3/4-16 threads. The IN and OUT ports are 1/2 inch NPT thread.
The hose fittings used on this thermostat plate are Aeroquip FBM5008 -8 AN to 1/2 inch NPT: https://www.summitracing.com/parts/AER-FBM5008.

The thermostat sandwich plate below is the one without the body mount bracket. This plate allows oil flow through the filter when cold, but will restrict flow to the oil cooler until it reaches temperature. When cold, the oil goes through the filter and returns to the engine.
This is Hayden PN 205: https://www.summitracing.com/parts/hda-205. The IN and OUT ports are 3/8 inch NPT thread.
The hose fittings used on this thermostat plate are Aeroquip FBM5007 -8 AN to 3/8 inch NPT: https://www.summitracing.com/parts/AER-FBM5007.


Here's the remote filter mounted in place just ahead of the front-right tire.  I made a mounting bracket from sheet metal. It's a very convenient place to change filters.

The 90 degree fittings on the thermostat plate are AN -8 90 degree Aeroquip Socketless hose ends: https://www.summitracing.com/parts/aer-fbl1533.

The 45 degree fittings on the oil filter mount are AN -8 45 degree Aeroquip Socketless: https://www.summitracing.com/parts/aer-fbl1523.

This photo is peeking just under the front spoiler. The bottom of the plumbing is about 2 inches higher than the bottom of the front spoiler.

And here's a pic with the belly pan in place.  It has a few snips to the plastic to make thing
s fit.

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