BIC Volvo S60R Front Mount Intercooler System - Manual (Page 13)

Volvo S60R Intercooler System / Installation Manual 11
Bell Intercoolers, inc. © 2009 All rights reserved. S601-S60R-IMv3
7.3 Reinstall Bumper Reinforcing Bar
• Position bumper reinforcing bar and install using inner bumper spac-
ers (one per side) and fasteners (see in Fig. 7.4). Do not tighten. If
bolt does not align with hole you may need to adjust frame mounting
tabs (see Fig. 7.3)
• Position and install outer bumper spacers and fasteners as shown in
figures 7.4 and 7.7. Do not tighten.
• Position and install outboard radiator bulkhead spacers and fasten-
ers as shown in figures 7.4 and 7.6. Do not tighten.
• Using intercooler mounting bolts (M10-1.25x80) as guides, position
inboard radiator bulkhead spacers.
• Install outboard radiator bulkhead spacers and fasteners (M8-1.25 x
40 bolts, washers and locknuts). Do not tighten.
• Tighten bumper reinforcing bar and radiator bulkhead fasteners in
the following sequence (see Figs. 7.4 and 7.5):
1) Inner bumper bolts (one per side)
2) Outer bumper bolts - Center (three per side)
3) Outer bumper bolts - Upper and Lower (two per side)
4) Radiator bulkhead bolts (one per side)
• Remove intercooler mounting bolts that were used as guides from
radiator bulkhead mounting point, leaving spacers in place.
Figure 7.7 Figure 7.6
Mounting Tabs
(Frame)
Inner Spacer
Top View
Outer Spacer
Top View
Inner
Spacer
Outer
Spacer
Bumper
Reinforcing
Bar
Canted
Washers
Front
Figure 7.5
Inner
Mounting
Point
Outer
Mounting
Point
Grill
Opening
Headlight
Radiator Bulkhead Mounting Tab Detail
M10-1.25 x 80
M8-1.25 x 40
Figure 7.2
Mounting
Tabs
Figure 7.3
Inner Tab
New
Position
Original
Position
Front
Outer Tab
New
Position
Original
Position
Mounting Tab Bend
Figure 7.4
Outer Inner
M8-1.25 x 40
M8-1.25 x 40
M10-1.5 x 60
M10-1.5 x 45