BIC Volvo V70R Front Mount Intercooler System User Manual

Page 10

Volvo V70R Intercooler System

/ Installation Manual

• Remove horns and original brackets. Locate and remove bolts

securing the twin horns in the upper grill opening. Note orientation
of horns. The horns are secured with one bolt per horn. Discon-
nect wiring connector from each horn. Remove horns and label as
“Right” and “Left.”

• Remove factory brackets from each horn. Secured with a single bolt

which will be used to attach the new horn brackets.

• The factory horns have a trumpet style shape and the opening of

that shape is in close proximity to the top of the new intercooler. This
proximity can reduce the effective volume level of the horns and we
recommend that you trim the horn trumpet slightly to allow for proper
horn volume.

Referring to Figure 5.3, trim each horn using a hacksaw.

• Identify new left and right brackets and attach to horns as shown in

Figure 5.2 (Left side horn and bracket shown, reverse for right side).
Tighten bolts. Note: Left refers to passenger side, right to driver side.

• Place horns into grill opening, behind power steering cooler and in-

stall using the supplied nuts, bolts and washers. Note that the horns
are now rotated 90º from their original position. Figure 5.1 shows
the horns in their new positions (power steering cooler not shown)
with mounting bolts for brackets facing up, rather than forward. Note
position of wiring connectors, these should face forward. Align horns
and tighten.

• Attach wiring connectors to each horn.

5.2 Trim Radiator Bulkhead
Note: This step involves cutting and/or grinding to remove metal from
the upper radiator bulkhead. This material is removed the enlarge the
opening for the AC charging port. A hacksaw and ﬁle or a Dremel tool
with cutting wheel and grinder will accomplish the job with little difﬁ-
culty. However, if you are not comfortable with tackling this job yourself,
any good paint and bodyshop will be able to do this for you.

• Locate AC charging port opening in radiator bulkhead. It is located

just above the left edge of the upper grill opening, as shown in
Figure 5.3 and Figure 5.4b (detail).

Figure 5.2

Left Horn/Bracket

Assembly

Bracket

(Left)

Horn

(Left)

Mounting Bolt

Wiring

Connection

Front

Figure 5.3

Trim

Line

Trimmed

AC Charging

Port

Figure 6.4a

Figure 6.3

Figure 6.4c

Figure 6.4b

3”