BIC Volvo S40 T5 Front Mount Intercooler System User Manual

Page 3

Volvo S40 T5 Intercooler System

/ Installation Manual

Required Tools and Materials

To efﬁci
supplied with your intercooler.

Tools

• 1/4” Drive Ratchet

• T20 and T30 Torx Bits and Suitable Driver

• 1/4” Drive Extensions - 3” Length

• Small Flat-head Screwdriver

• 3/8” Drive Ratchet

• Phillips Screwdriver

• 3/8” Drive Extension - 3” Length

• Hacksaw or Cutting Wheel

• Sockets 8 - 17 mm (1/4” or 3/8” Drive)

• Round and Flat File (optional)

• 11 mm Deep Socket

• Vehicle Jack or Lift

• Wrenches (Open/Boxed) 8 - 17 mm

• Jack Stands (x2)

• Straight Edge Ruler

Materials

• WD-40, Motor Oil or Lubricant

• Grease Pencil or China Marker (non-permanent)

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 inlet tube can cause serious and expensive damage when the engine is
started, possibly damaging valves, cylinders and pistons. An easily avoidable, but expensive proposition.

While performing the installation keep the any open intake tubes (air
intake, etc.) covered with a clean rag and thoroughly check all tubes,
hoses and the intercooler for any foreign objects or debris before
installing.

1.1 Disconnect Battery
As a matter of safety you should disconnect the negative battery
terminal before beginning any work on this installation. This is done
to prevent any unintentional shorting of electrical components and to
remove the danger of accidentally energizing the starter motor with
a tool.

The battery is located in the right rear corner of the engine and is
covered.

• Locate battery and remove cover (Fig. 1.1). To remove cover

pull out on sides and lift front.

• Disconnect the negative terminal (Fig. 1.2) and move battery

cable away from negative post.

1.2 Jack Stands or Lift
Installation of this intercooler system can be accomplished
without placing the vehicle on a lift or jack stands. However,
you will ﬁnd the installation process much easier with the car
elevated. If you will be lifting the car please consult Volvo ser-
vice manual proper jack, jack stand and/or lift placement. Be
sure vehicle is securely positioned before proceeding.

1.0

Figure 1.1

Figure 1.2

Battery

Cover

Negative

Terminal