BIC Volvo S60R Front Mount Intercooler System - Manual (Page 11)

Volvo S60R Intercooler System / Installation Manual 9
Bell Intercoolers, inc. © 2009 All rights reserved. S601-S60R-IMv3
Drilling, Trimming and Misc.
6.1 Installing Horn Brackets
Installation of the larger intercooler requires the use of new horn brackets. These brackets rotate the horns from their original ver-
tical position in the upper grill opening to a horizontal position (see Fig. 6.1). The following brackets and fasteners are provided
with your intercooler system:
New Components
Horn Bracket - Left (x1)
Horn Bracket - Right (x1)
M6-1.0 x 20mm Bolt - Hex Head (x2)
M6-1.0 Hex Nut (Mechanical Locknut) (x2)
M6 Washer (x4)
• Remove horns and original brackets. Locate and remove
bolts securing the twin horns in the upper grill opening.
Note orientation of horns. The horns are secured with
one bolt per horn. Disconnect wiring connector from each
horn. Remove horns and label as “Right” and “Left.”
• Remove factory brackets from each horn. Secured with a
single bolt which will be used to attach the new horn brackets.
• The factory horns have a trumpet style shape and the opening of
that shape is in close proximity to the top of the new intercooler. This
proximity can reduce the effective volume level of the horns and we
recommend that you trim the horn trumpet slightly to allow for proper
horn volume.
Referring to Figure 6.3, trim each horn using a hacksaw.
• Identify new left and right brackets and attach to horns as shown
in Figure 6.2 (Left side horn and bracket shown, reverse for right
side). Tighten bolts. Note: Left refers to passenger side, right to
driver side.
• Place horns into grill opening, behind power steering cooler and
install using the supplied nuts, bolts and washers. Note that the
horns are now rotated 90º from their original position. Figure 6.1
shows the horns in their new positions (power steering cooler not
shown) with mounting bolts for brackets facing up, rather than for-
ward. Note position of wiring connectors, these should face forward.
Align horns and tighten.
• Attach wiring connectors to each horn.
6.2 Trim Radiator Bulkhead
Note: This step involves cutting and/or grinding to remove metal from
the upper radiator bulkhead. This material is removed the enlarge the
opening for the AC charging port. A hacksaw and file or a Dremel tool
with cutting wheel and grinder will accomplish the job with little diffi-
culty. However, if you are not comfortable with tackling this job yourself,
any good paint and bodyshop will be able to do this for you.
• Locate AC charging port opening in radiator bulkhead. It is located
just above the left edge of the upper grill opening, as shown in
Figure 6.3 and Figure 6.4b (detail).
• Using a grease pencil draw a line straight back from the edge of the
existing hole in the radiator bulkhead (Items A in Figure 6.4b).
• Draw a line across, connecting the two previous lines, 3 inches from
the bottom of the opening (Item B in Figure 6.4b).
!
Figure 6.1
Horn (Left)
Final Horn Position
Upper Grill Opening
(from front)
Horn (Right)
Mounting
Point
Mounting
Point
Figure 6.2
Left Horn/Bracket
Assembly
Bracket
(Left)
Horn
(Left)
Mounting Bolt
Wiring
Connection
Front
6.0
Figure 6.3
Trim
Line
Trimmed