BIC Volvo S60R Front Mount Intercooler System - Manual (Page 12)

Volvo S60R Intercooler System / Installation Manual 10
Bell Intercoolers, inc. © 2009 All rights reserved. S601-S60R-IMv3
• Radius each of the upper corners as shown in Figure 6.4b. A .5” radius is shown.
Using a hacksaw or cutting tool, cut carefully along lines. Exercise care to avoid damaging the radiator. Smooth edges with flat
and round files. Figure 6.4c shows the finished AC charging port opening shape.
• Coat any exposed metal with touch-up paint.
• Properly reposition radiator and AC condenser assembly and tighten two (2) bolts securing top of radiator to radiator bulkhead.
• Tighten two (2) bolts securing radiator to vehicle (see Items B in Fig. 5.4).
• Reinstall upper and lower radiator hoses and refill engine coolant with specified type and quantity. Close coolant reservoir cap.
Reinstall Bumper Reinforcing Bar
New Components
Bumper Spacer - Outer (x2) M8-1.25 x 40mm Bolt - Hex Head (x6)
Bumper Spacer - Inner (x2) M8-1.25 Hex Nut (Mechanical Locknut) (x6)
Radiator Bulkhead Spacer (x4) M8 Washer (x8)
M10-1.5 x 60mm Bolt - Hex Head (x2) M8 Washer - Canted (x4)
M10 Washer - Canted (x4) M10-1.5 x 45mm Bolt - Hex Head (x2)
M10 Washer (x4)
7.1 Remove Plastic Backing Plate
• Remove plastic backing plate from bumper reinforcing bar. This backing
plate is secured with two plastic rivets which can be removed by tapping
out the center section. (see Fig. 7.1).
7.2 Adjust Mounting Tabs
• Locate inboard and outboard bumper bar mounting tabs on vehicle
frame (see Fig. 7.2). These are the large mounting points that secure
the bumper reinforcing bar.
• Using vise-grip type pliers gently bend the outboard tabs forward so they
are aligned with front face of AC condenser (see Fig. 7.3). These tabs
are easy to bend and the bend does not need to be exact, as the tabs will
conform to the angle of the bumper reinforcing bar spacers when tightened.
• Bend inboard tabs back so they are parallel with front face of AC con-
denser (see Fig. 7.3).
7.0
AC Charging
Port
Figure 6.4a Figure 6.3 Figure 6.4c Figure 6.4b
3”
A A
B
Figure 7.1
Plastic Backing
Plate
Bumper
Reinforcing
Bar
(back)