BIC Volvo S40 T5 Front Mount Intercooler System - Manual (Page 9)

Volvo S40 T5 Intercooler System / Installation Manual 7
Bell Intercoolers, inc. © 2009 All rights reserved. S40-IMv1
Trim and Install Front Fascia (Nose Section)
This step requires relatively easy trimming of the plastic and urethane components of the front fascia. All trimming can be easily
accomplished with a hacksaw or cutting wheel and cleaned up with a file and sand paper.
6.1 Remove Lower Grill Insert
The
6.2 Mark Lower Grill Opening
To provide adequate room for the new
intercooler it is necessary to trim the back
of the lower grill opening.
• At each corner of bottom surface mark
a line 1 5/8” from back edge (see Fig.
6.1).
• At each corner of top surface mark a
line 3/4” from back edge (see Fig. 6.1).
• Using a straight edge, mark line across
bottom surface connecting corner marks
(see Fig. 6.1).
• Repeat for top surface (see Fig. 6.1).
• 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. The finished cut can
be seen in Figure 6.2.
6.3 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.
• Lift fascia and guide into position.
• Guide tabs below headlights into posi-
tion.
• 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.
• Check fascia for proper fit and align-
ment against fenders and headlights.
Adjust as necessary.
6.0
Figure 6.1
Figure 6.2
Figure 6.3
Trimmed Lower Grill Opening
Trimmed Fascia Installed
(Upper Corner)
Mark 3/4”
From Back Edge
(Lower Corner)
Mark 1 5/8”
From Back Edge
Upper
Cut Line
Bottom
Cut Line
(Lower Corner)
Mark 1 5/8”
From Back Edge
(Upper Corner)
Mark 3/4”
From Back Edge