BIC Volvo S60R Front Mount Intercooler System User Manual

Page 9

Volvo S60R Intercooler System

/ Installation Manual

5.4 Drain Engine Coolant
Note: You may wish to replace your engine coolant and radiator hoses as
part of routine maintenance.

• Locate the plastic radiator drain plug/nozzle at the lower right (driver side)

corner of the radiator (see Fig. 5.2).

• Remove cap from coolant reservoir in engine compartment.

• Position drain pan and loosen, but do not remove drain plug. Coolant will

drain without the drain plug being completely removed.

• When coolant completely drained, retighten coolant drain plug.

5.5 Disconnect Radiator Hoses
• Loosen hose clamps securing upper and lower radiator hoses to radiator.

• Disconnect upper and lower radiator hoses from radiator. Remove

hoses completely if replacing with new hoses.

5.6 Remove Cooling Fan Assembly
• Locate and remove two (2) bolts securing cooling fan assembly to

radiator. These will be located at the upper corners of the cooling fan
assembly.

• Disconnect fan wiring harness.

• Lift fan assembly to disengage two (2) mounting tabs near bottom of

fan assembly.

• Carefully lift cooling fan assembly from behind radiator, being sure

not to damage radiator cooling ﬁns or core when extracting the fan
assembly.

5.7 Remove Primary Intercooler
Note: The AC condenser, intercooler and radiator are lowered
together (see Fig. 5.3) before removing the intercooler. The AC
condenser is not completely removed from the vehicle and the AC
lines are NOT disconnected during this process. Care must be given
to ensure the AC lines and connections are not damaged during this
process.

• Locate wiring connector on AC condenser, on passenger side,

attached to AC Dryer (silver canister). Disconnect connector.

• Locate and remove the two (2) bolts securing top of radiator to

radiator bulkhead.

• Locate the four bolts connecting the AC condenser, primary

intercooler and radiator (see Items A in Fig. 5.4). Remove the two
upper connecting bolts. Remove the two lower connecting bolts.

• Locate and remove the two (2) bolts securing the radiator to the

vehicle (see Items B in Fig. 5.4). Carefully lower radiator, AC
condenser and intercooler into position shown in Fig. 5.3.

• Carefully separate AC condenser and radiator from intercooler

and remove intercooler. It will be necessary to extract the inter-
cooler towards the top of the AC condenser and radiator due to
the various AC lines. Exercise care to avoid damaging AC con-
denser and radiator ﬁns during this process.

Figure 5.4

Illustration / Volvo Cars North America

Radiator/AC Condenser/Intercooler

Mounting Points

Radiator

Figure 5.2

Coolant

Drain Plug

Figure 5.3