BIC Volvo S60R Front Mount Intercooler System User Manual

Page 4

Volvo S60R Intercooler System

/ Installation Manual

Required Tools and Materials

To efﬁci
supplied with your intercooler.

Tools

• 1/4” Drive Ratchet

• .457” Drill Bit (or next larger size available)

• 1/4” Drive Extensions - 3” and 6” Length

• .312-.328” Drill Bit (or next larger size available)

• 3/8” Drive Ratchet

• Vise-Grip style locking pliers (2 required)

• 3/8” Drive Extension - 3” Length

• Small Trim/Molding Removal Tool (or Butter Knife)

• Sockets 8-17mm (1/4” or 3/8” Drive)

• Hacksaw or Cutting Wheel

• 11 mm Deep Socket

• Round and Flat File

• Wrench (Open/Boxed) 8-17mm

• Ruler – 12” or longer

• T-25 and T-15 Torx Bits

• Vehicle Jack or Lift

• Flat-head Screwdriver

• Jack Stands (x2)

• Phillips Screwdriver

• Carpet Knife (Optional)

• Electric Handheld Drill (capable of holding .5” bit)

* Butane or Propane Torch (Optional)

• Drain Pan for Engine Coolant

Materials

• Grease Pencil or China Marker (non-permanent)

• Masking Tape

• Black Ink Marker Pen (Sharpie™)

• Sandpaper - 600 Grit

• Satin Black Touch Up Paint

Vehicle Preparations

As with any vehicle modiﬁcation project, the process will be easier, faster and safer for the engine, turbocharger and you if the en-
gine compartment is thoroughly cleaned before you begin the project. Not only is a dirty engine compartment a mess to work in, but
a dirty engine compartment also offers the possibility that dirt and/or debris could be introduced into the intake tract of the engine.

A small stone or piece of debris falling into an open turbo inlet can cause serious and expensive damage to the turbo when the
engine is started. Even worse, the debris could cause a turbocharger compressor failure leading to pieces of compressor blades
feeding into the cylinder, possibly damaging valves, cylinders and pistons. An easily avoidable, but expensive proposition.

Wh
all tubes, hoses and the intercooler for any foreign objects or debris before installing.

1.1 Disconnect Battery
Before beginning any work on this installation disconnect the negative terminal of the battery. During the installation you will have

ba
your Volvo service manual for details and procedures on disconnecting the trunk mounted battery.

1.2 Jack Stands or Lift
Installation of this intercooler system requires placing the vehicle on a lift or jack stands. Please consult Volvo service manual
proper jack, jackstand and/or lift placement. Be sure vehicle is securely positioned before proceeding.

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