BIC Volvo V70R Front Mount Intercooler System User Manual

Page 12

Volvo V70R Intercooler System

/ Installation Manual

• Move intercooler into position in front of AC condenser. Be careful

not to damage cooling ﬁns on Intercooler or AC condenser.

• Install mounting fasteners and spacers through as shown in

Figure 6.3. Be sure spacers are rotated as shown, with widest
section to the bottom, to ensure proper spacing between the inter-
cooler and AC condenser.

• Align bottom edge of Intercooler to bottom edge of radiator / AC

condenser Assembly and tighten mounting fasteners.

• Check for proper alignment and spacing between intercooler and

AC condenser (approximately .5”) and parallel mounting to the AC
condenser.

Installing New Intercooler Tubes

New Components

Intercooler Inlet Tube

(x1)

Hose Clamp (T-Bolt) - 3.0”

(x2)

Intercooler Outlet Tube

(x1)

Silicone Hose - Straight 2.5” Dia.

(x1)

Throttle Inlet Tube

(x1)

Silicone Hose - Straight 3.0” Dia.

(x1)

Hose Clamp (T-Bolt) - 2.0” or 2.25”

(x1)

Silicone Hose - Bellows 2.5” Dia.

(x2)

Hose Clamp (T-Bolt) - 2.5”

(x7)

Silicone Hose - Reducer 2.0” or 2.25” - 2.5” Dia. (x1)

Note: To ensure the intercooler tubes are securely installed you will need to properly position the silicone hose and hose clamps
in

of the tube under high boost pressure.

er tubes mark all tubes with a line 1” in from the bead. This will allow you be sure the clamp and hose are properly positioned.

Hose clamps should be tightened to the point where the silicone hose cannot be rotated against the metal tube. Overtightening
can result in cutting and damaging the silicone hose.

7.4b and 7.4c to allow for easy access for tightening while not rubbing on the front fascia bodywork.

7.1 Relocate Wiring Harness
To avoid damage to wiring harness due to close proximity to acces-
sory drive belt and pulley it is necessary to relocate a short portion of
the wiring harness. This section of wiring harness is located behind
radiator and lower left corner of radiator and runs between the engine
and the radiator. To relocate this section you will disconnect the tabs
securing the harness, wrap the harness in a poly wire loom (provided
with system) and relocate the harness closer to the radiator. Care
must be exercised when working with the wiring harness so as not to
damage any of the wires.

• Locate wiring harness. Harness is located between the radiator and

engine near lower left corner of radiator. Note position of harness
in relation to crossmember and radiator. Harness will be moved
forward towards radiator.

• Locate and remove bolt securing wiring harness guide to engine

crossmember.

• Separate two halves of wiring guide. Carefully clip zip ties as

needed so as not to damage any wires.

7.0

Figure 7.1

Intercooler

Inlet Tube

Intercooler

Outlet Tube

Throttle

Inlet Tube

Figure 6.3

Intercooler

Bracket

Bumper

Cross Member

Spacer

Wide

Narrow

Bracket and Fastener Diagram