BIC Volvo V70R Front Mount Intercooler System User Manual

Page 11

Volvo V70R Intercooler System

/ Installation Manual

• Using a grease pencil draw a line straight back from the edge of the existing hole in the radiator bulkhead (Items A in Figure

5.4b).

• Draw a line across, connecting the two previous lines, 3 inches from the bottom of the opening (Item B in Figure 5.4b).
• Radius each of the upper corners as shown in Figure 5.4b. A .5” radius is shown.

Using a hacksaw or cutting tool, cut carefully along lines. Exercise care to avoid damaging the radiator. Smooth edges with ﬂat
and round ﬁles. Figure 5.4c shows the ﬁnished AC charging port opening shape.

• Coat any exposed metal with touch-up paint.

• Properly reposition radiator and AC condenser assembly and tighten two (2) bolts securing top of radiator to radiator bulkhead.

• Tighten two (2) bolts securing radiator to vehicle (see Items B in Fig. 4.4).

• Reinstall upper and lower radiator hoses and reﬁll engine coolant with speciﬁed type and quantity. Close coolant reservoir cap.

5.3 Enlarge Intercooler Mounting Bracket Holes
• Locate the two holes to be used for new intercooler mounting brackets. These are located on either side of the upper grill

opening and are attached to a ﬂange at the back of the bumper cross member (as shown in Figures 5.5a and 5.5b). A detail
photo is shown in Figure 5.6.

• Using the .457 drill bit, enlarge each of the two holes. The holes are only approximately .25” deep, only drill deep enough to

properly enlarge the holes to prevent damage to radiator.

Installing New Intercooler

New Components

AC Condenser / Radiator Spacer

(x4)

M10-1.25 x 60mm Bolt - Hex Head

(x2)

M6-1.0 x 40mm Bolt - Hex Head

(x4)

M10 Washer

(x4)

M6 Washer

(x4)

M10-1.25 Hex Locknut (Mechanical)

(x2)

Intercooler

(x1)

Intercooler Spacer

(x2)

6.1 Install New Intercooler
Th
installed properly there will be approximately a .5” gap between the Intercooler face and the AC condenser face. The Intercooler
should be parallel to the AC condenser.

Pay

intercooler will not align with the AC condenser face.

6.0

Figure 5.5b

Figure 5.5a

Mounting

Hole

Mounting

Hole

Left Side

Right Side

Figure 5.6

Left Side - Detail

Figure 6.2

Inlet

Outlet

Bracket

Intercooler - Front View

Bracket