BIC VOLVO C30 T5 - Manual (Page 10)

Volvo C30 T5 Intercooler System / Installation Manual 8
Bell Intercoolers, inc. © 2009 All rights reserved. C30-IMv1
• Draw lines on side surfaces connecting
upper and lower corners (see Fig. 6.1).
• Using hacksaw or cutting wheel, care-
fully cut along lines.
• Carefully clean up cut edges with file
and/or sandpaper.
6.4 Reinstall Front Fascia
Reinstall front fascia in reverse sequence
of removal process (see Step 2.0, pg 2).
• Position front fascia in front of car and
connect driving light wiring connectors
(if so equipped).
• Lift fascia and guide into position.
• Guide tabs below headlights into
position.
• Guide upper fender tabs into position at each corner of the upper radiator bulkhead.
• Guide lower corners of fascia over fender liners (one per side).
• Gently press fascia into position.
• Guide three mounting tabs into position along lower radiator support.
• Press fender tabs into position on each side.
• Check fascia for proper fit and alignment against fenders and headlights. Adjust as necessary.
• Reinstall plastic rivets and fasteners across upper radiator bulkhead.
• Reinstall headlight washer covers (if so equipped).
• Clip fender lips into position, repeat for both sides.
• When installed, there should be a 1/8” - 1/4” gap between the intercooler surface and the back of the lower grill opening (see
Fig. 6.3).
6.4 Reinstall Splash Guard
Reinstall splash guard in reverse sequence of removal process (see Step 2.2, pg 2).
• Reinstall and tighten seven (7) T30 Torx fasteners securing splash guard.
Test Drive and System Checks
Testing should be done with the radio and AC/heat fan off and with all windows rolled up to allow you to properly hear the engine.
Allow engine to reach operating temperature and make certain the engine is running smoothly and normally, both at idle and
under load, prior to applying boost.
It
position. This is also the time to check for any potential clearance issues.
Installation is now complete.
7.0
Figure 6.3 Trimmed Fascia Installed