BIC Volvo S60R Front Mount Intercooler System User Manual
Page 14
Volvo S60R Intercooler System
/ Installation Manual
12
Bell Intercoolers, inc. © 2009 All rights reserved. S601-S60R-IMv3
Installing New Intercooler
New Components
AC Condenser / Radiator Spacer
(x4)
Intercooler
(x1)
M10-1.25 x 80mm Bolt - Hex Head
(x2)
Intercooler Spacer
(x2)
M10-1.25 Hex Nut (Mechanical Locknut)
(x2)
M10 Washer
(x4)
8.1 Install New Intercooler
The new Intercooler will be installed with the mounting brackets
facing forward. When the Intercooler and Intercooler Spacers are
installed properly there will be approximately a .5” gap between the
Intercooler face and the AC condenser face. The Intercooler should
be parallel to the AC condenser.
Pay special attention to the position of the intercooler spacers.
Each of the two spacers has an angled face and must be installed
with the wide section of the spacer facing down (see Figure 8.2). If
these intercooler spacers are not correctly positioned the inter-
cooler will not align with the AC condenser face.
• Move intercooler into position in front of AC condenser. Be care-
ful not to damage cooling fins on Intercooler or AC condenser.
• Install mounting fasteners and spacers through as shown in
Figure 8.2. Be sure spacers are rotated as shown, with widest
section to the bottom, to ensure proper spacing between the
intercooler 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)
Poly Wire Loom
(x1)
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)
Hose Clamp (T-Bolt) - 3.0”
(x2)
Note: To ensure the intercooler tubes are securely installed you will need to properly position the silicone hose and hose clamps
in
f
of the tube under high boost pressure.
Fo
-
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.
9.0
Figure 8.2
Intercooler
Bracket
Bumper
Cross Member
Radiator
Bulkhead
Intercooler
Spacer
Radiator Bulkhead
Spacer
Bracket and Fastener Diagram
Figure 8.1
Inlet
Outlet
Bracket
Intercooler - Front View
Bracket
8.0