BIC VOLVO C30 T5 - Manual (Page 7)

Volvo C30 T5 Intercooler System / Installation Manual 5
Bell Intercoolers, inc. © 2009 All rights reserved. C30-IMv1
the on the factory intercooler. Refer to Figure 4.1 to ensure proper
orientation of the sensor relative to the intercooler.
• Apply a thin coating of motor oil to the IAT sensor o-ring.
• Carefully insert sensor into new intercooler. Position as shown in
Figure 4.1.
• Install M5- 0.8 x 20mm bolt and M5 washer (supplied with inter-
cooler kit) to secure fastener. Tighten fastener.
4.2 Install T-Bolt Hose Clamps
The T-Bolt hose clamps must be installed prior to installing the inter-
cooler. Refer to Figures 4.2 and 4.3 for proper orientation of clamps
to allow for correct clearance of the clamp bolts after installation.
• Position hose clamps on intercooler inlet and outlet hoses. Do not
tighten.
4.3 Install Intercooler
The new intercooler will mount using new fasteners supplied with
the kit. These fasteners will install in place of the factory fasteners
securing the lower radiator crossmember that you removed in step
3.7. Be aware that you will be reconnecting the IAT sensor harness to
the intercooler after installation. Place wiring harness so it does not
become trapped or restricted during installation of intercooler.
• Move intercooler into position with mounting brackets located as
shown in Figures 4.4 and 4.5. Be sure hose clamps are in position
as described in step 4.2.
• Installed M8 - 1.25 x 60mm bolt and M8 washer at each mounting
point. Do not tighten fasteners.
• Position intercooler so there is a consistent gap of approximately
1/8” between the intercooler and the radiator assembly (see Fig.
4.6). When this gap is established, tighten mounting fasteners.
4.4 Reconnect IAT Sensor Wiring Harness
• Reconnect wiring harness to IAT sensor. Check to be sure wiring
harness is not restricted, kinked or pinched by intercooler. Adjust if
necessary.
4.5 Install Intercooler Inlet and Outlet Hoses
For proper installation the hose clamps must be positioned behind
the hose bead as shown in Figure 4.7. Before installation of intercool-
er hoses mark all intercooler tubes with a line 1” in from the bead, as
shown in Figure 4.7. This will allow you be sure the clamp and hose
are properly positioned. There should be approximately 1/8” between
the edge of the hose and the edge of the clamp when installed.
Hose clamps should be tightened to the point where the hose cannot
be rotated against the metal tube. Overtightening can result in cutting
and damaging the hose.
• Slide intercooler inlet and outlet hoses onto intercooler.
• Position and tighten T-bolt hose clamps. Clamps should be posi-
tioned as shown in Figures 4.2 and 4.3. Be sure that the clamp bolts
do not contact any surrounding components. Adjust as necessary.
Figure 4.1
Figure 4.2
Figure 4.3
IAT
Sensor
Hose
Clamp
Hose
Clamp