BIC Volvo S60R Front Mount Intercooler System - Manual (Page 17)

Volvo S60R Intercooler System / Installation Manual 15
Bell Intercoolers, inc. © 2009 All rights reserved. S601-S60R-IMv3
9.5 Install Hoses and IAT Sensor
• Reinstall vacuum/boost hose, attaching to hose boss on throttle inlet
tube (see Fig. 9.5).
• Using supplied bolt and washer, reinstall IAT sensor attaching to
mounting boss on intercooler outlet tube as shown (see Fig. 9.5).
• Reconnect IAT sensor wiring harness.
9.6 Recheck Clearances and Hose Clamps
Before proceeding, recheck all tube clearances. Also recheck all hoses
and hose clamps to ensure they are properly positioned to the bead
reference lines and are properly tightened. Be sure to check both hose
clamps at the throttle inlet.
At this time also check for any wiring harnesses or other components
that may have come loose during the installation. This is especially
important in the area surrounding the engine drive belts as any loose
wiring or component that comes into contact with this belt could be
severely damaged.
15 minutes spent looking for potential problems now can prevent ex-
pensive and/or dangerous damage later.
Reinstall Air Filter Assembly
Reinstall air filter box in reverse sequence of removal (Section 3.0, pg. 4).
• Reattach vacuum line bundle to tab on side of air filter box.
• Insert air filter outlet into air inlet tube. This tube will snap in place when properly positioned.
• Reconnect mass air sensor harness.
• Install three bolts securing air filter box. Only tighten lower right bolt, leave others loose so air filter box can be shifted during
installation of cold air snorkel.
• Insert cold air snorkel into slot in radiator bulkhead. Be sure the snorkel fits over receiver within the radiator bulkhead.
• Install bolts securing cold air snorkel to radiator bulkhead. Tighten.
• Insert other end of cold air snorkel into air filter box. Be sure tabs engage.
• Install bolts securing cold air snorkel to air filter box and tighten.
• Tighten remaining two air filter box bolts.
• Tighten hose clamp connecting air filter box to air inlet tube.
Start Engine and Check Connections
NOTE: PRIOR TO STARTING ENGINE BE SURE RADIATOR HOSES ARE SECURELY REINSTALLED AND ENGINE COOL-
ANT HAS BEEN REPLACED AND IS AT RECOMMENDED LEVEL. FAILURE TO REPLACE COOLANT CAN RESULT IN
SEVERE ENGINE DAMAGE.
Be
check the engine and make sure all components are functioning properly. The car will not be driven at this time, but this will allow
you to determine that all wiring harnesses, vacuum/boost lines, and intercooler tubes have been connected properly.
11.0
10.0
!
Figure 9.5
Vacuum/Boost
Hose
IAT Sensor