BIC Volvo S60R Front Mount Intercooler System - Manual (Page 15)

Volvo S60R Intercooler System / Installation Manual 13
Bell Intercoolers, inc. © 2009 All rights reserved. S601-S60R-IMv3
The hose clamps for the intercooler inlet tube and intercooler outlet
tube may positioned as shown in Figures 9.3a, 9.3b, 9.4a, 9.4b and
9.4c to allow for easy access for tightening while not rubbing on the
front fascia bodywork.
9.1 Relocate Wiring Harness
To avoid damage to wiring harness due to close proximity to acces-
sory drive belt and pulley it is necessary to relocate a short portion of
the wiring harness. This section of wiring harness is located behind
radiator and lower left corner of radiator and runs between the engine
and the radiator. To relocate this section you will disconnect the tabs
securing the harness, wrap the harness in a poly wire loom (provided
with system) and relocate the harness closer to the radiator. Care
must be exercised when working with the wiring harness so as not to
damage any of the wires.
• Locate wiring harness. Harness is located between the radiator and
engine near lower left corner of radiator. Note position of harness
in relation to crossmember and radiator. Harness will be moved
forward towards radiator.
• Locate and remove bolt securing wiring harness guide to engine crossmember.
• Separate two halves of wiring guide. Carefully clip zip ties as needed so as not to damage any wires.
• Extract wiring harness from guide to just past securing bolt.
• Using a hacksaw or suitable cutting tool carefully cut wire guide .5” outboard of mounting tab securing guide. Cut both halves
of guide. Remove cut section of guide.
• Using electrical tape carefully wrap exposed wiring harness to keep loose wires bundles. Use tie wraps to secure taped bundle
every six inches.
• Carefully insert exposed wiring harness into poly wire loom (provided with system). Secure ends of wire loom with tie wraps.
• Reposition fully wrapped wiring harness forward towards radiator. Harness will be held away from accessory drive belt and pulley
by intercooler inlet tube.
9.2 Install Intercooler Inlet Tube
• Mark both ends of intercooler inlet tube with line 1” from bead (see Fig. 9.2).
• Position silicone reducer hose (2.25” - 2.5” dia.) and 2.25” hose clamp on
over-engine-pipe (tube running forward across top of engine). Position hose
clamp so it will not contact any surrounding components during engine
movement (approx. .25” gap). Tighten clamp.
• Position second hose clamp (2.5”) on opposite end of silicone reducer hose.
• Install bellows (hump) silicone hose (2.5” dia.) and 2.5” hose clamp on In-
tercooler inlet (see Figs. 9.3a and 9.3b). Position properly behind bead and
tighten hose clamp (see Fig. 9.2).
• Position a second hose clamp (2.5”) on opposite end of silicone bellows
hose at Intercooler inlet.
• Install intercooler inlet tube. Both ends of tube will be inserted into the re-
spective hoses at the same time.
• Position tube so it will not contact any surrounding components, a .25” gap
should be sufficient to allow for engine movement.
• Position wiring harness forward towards radiator.
• When tube is properly positioned, tighten hose clamps.
Hose and Clamp Placement Diagram
Intercooler
Tube
Silicone
Hose
Hose
Clamp
Retaining
Bead
1”
Mark
Line
Figure 9.2
Figure 9.1
Intercooler
Inlet Tube
Intercooler
Outlet Tube
Throttle
Inlet Tube