BIC Volvo S60R Front Mount Intercooler System - Manual (Page 2)

Volvo S60R Intercooler System / Installation Manual
Bell Intercoolers, inc. © 2009 All rights reserved. S601-S60R-IMv3
Contents
Important Information 1
Parts List 1
Required Tools and Materials 2
1.0 Vehicle Preparation 2
2.0 Removing Front Fascia (Nose Section) 3
3.0 Removing Bumper Reinforcing Bar 4
4.0 Removing Air Filter Assembly 5
5.0 Removing Factory Intercoolers and Tubes 6
6.0 Drilling, Trimming and Misc. 9
7.0 Installing New Intercooler 10
8.0 Installing New Intercooler Tubes 12
9.0 Reinstalling Bumper Reinforcing Bar and Spacers 12
10.0 Reinstalling Air Filter Assembly 15
11.0 Start Engine and Check Connections 15
12.0 Trim and Install Front Fascia (Nose Section) Substructure 16
13.0 Trim and Install Front Fascia (Nose Section) 20
14.0 Test Drive 22
Important Information
Congratulations on your purchase of the Bell Intercoolers Volvo S60R Front Mount Intercooler System. The installation instruc-
tions in this manual will assist you in the complete process of installing your new intercooler. Please read through these instruc-
tions entirely before you begin the installation process. This will familiarize you with the process and alert you to any unique tools
or m
please do not hesitate to contact us at 210-412-0917.
however, it is important to honestly evaluate your mechanical skills and determine if you are capable of performing the installation
or if you should have the system installed by a professional mechanic. To help you identify possible difficulties, we have marked
steps of installation that are complex, require special tools or involve special procedures with this icon:
A modern internal combustion engine is a precise piece of equipment and while durable they can be severely damaged or de-
stroyed through careless installation techniques.
To
problems with the engine or vehicle corrected prior to installing the intercooler.
C
!
!