BIC Volvo S60R Front Mount Intercooler System - Manual (Page 16)

Volvo S60R Intercooler System / Installation Manual 14
Bell Intercoolers, inc. © 2009 All rights reserved. S601-S60R-IMv3
• On vehicles with small AC dryer canister
check for clearance issues with AC dryer line
and carefully adjust line position as needed.
• Carefully check for clearance issues with
wiring harness and adjust as needed. If the
harness is allowed to make contact with
the engine accessory drive belt or pulley it
will be damaged quickly and this damage
can be expensive.
Note: There is a small plastic tab located on
the back of the radiator assembly, for posi-
tioning the wiring harness, which may rub on
tube. If it does rub, carefully remove the tab
with a hacksaw and file rough edges.
9.3 Install Intercooler Outlet Tube
Note: Tube is equipped with a port to allow for installation of Aquamist water injection system. Remove port plug for use.
• Mark both ends of intercooler outlet tube with line 1” from bead, as shown in Figure 9.2.
• -
tion hose and clamp properly behind retaining bead and tighten hose clamp (see Fig. 9.2).
• Position a second hose clamp (2.5”) on opposite end of silicone hose. Note position of clamp (see Fig. 9.4c).
• Install intercooler outlet tube. Do not tighten clamps.
9.4 Install Throttle Inlet Tube
• Mark both ends of throttle inlet tube with line 1” from bead (see Figure 9.2).
• On la
hose extends past end of throttle inlet tube. You will need estimate position of hose clamp and test install onto throttle inlet to
determine final position. When final position is determined, tighten hose clamp.
• Position second hose clamp (3.0”) on silicone hose and install on throttle inlet. Be sure hose and clamp are seated squarely
against throttle inlet. Snug hose clamp to allow you to rotate hose into position with intercooler outlet tube.
• Install straight silicone hose (2.5” dia.) and hose clamp (2.5”) on other end of throttle inlet tube. Do not tighten.
• -
tioning hose and clamps according to bead reference line. Position tubes with a minimum of .25” of clearance to all surround-
ing components. Check that silicone hose and hose clamp at throttle inlet are still squarely seated against throttle inlet.
• Tighten hose clamps, including throttle inlet clamp.
• Recheck clearance of both tubes, providing a minimum of .25” of clearance from all surrounding components. Adjust as needed.
Figure 9.4a Figure 9.4c Figure 9.4b
Figure 9.3a Figure 9.3b