BIC Volvo S60R Front Mount Intercooler System - Manual (Page 18)

Volvo S60R Intercooler System / Installation Manual 16
Bell Intercoolers, inc. © 2009 All rights reserved. S601-S60R-IMv3
• Remove car from jack stands or lift.
• Reconnect battery.
• Start engine and allow engine to warm to operating temperature. Watch temperature gauge closely and check for function of
engine cooling fan. Shut off engine immediately if any gauges or engines lights indicate abnormal function.
• Engine should idle and rev normally. If it does not, shut off engine and check for loose intercooler tubes/hoses and discon-
nected wiring harnesses. Restart engine and check for normal idle and revs.
• Shut off engine and disconnect battery.
• Place car back on jack stands or lift to complete installation of front fascia bodywork.
Trim and Install Front Fascia (Nose Section) Substructure
This step requires relatively easy trimming of the plastic and styrofoam components of the front fascia substructure. All com-
ponents being trimmed or cut are replaceable, no permanent components are modified, to allow the vehicle to be returned to
original condition if so desired. All trimming can be accomplished with a hacksaw or cutting wheel, however use of a band saw, if
available, will greatly speed the process. After cutting clean all rough edges with a file and/or sand paper.
Note: To protect paint of the front fascia it is recommended the work area be clean and the fascia be placed on a soft cloth.
Please note, the trim lines shown in these photographs will result in a proper fit, however you may wish to remove less material.
12.1 Remove Plastic Substructure and Styrofoam
• Carefully place the front fascia on suitable work surface and remove fog light support braces from front fascia. One per side.
• Separate plastic substructure from front fascia. Plastic substructure is attached by numerous plastic clips.
• Separate styrofoam impact strip from plastic substructure.
• Using grease pencil mark a line 5/8” from front of styrofoam impact strip (see Fig. 12.2). Front section of styrofoam will be
discarded. Do not damage rear section during cutting as it will be reattached to the plastic substructure.
• Mark and trim plastic substructure as shown in Figures 12.3 - 12.10. This trimming is not exact, but should be close to what is
shown in photographs to allow proper fit of front fascia. All trimming can be accomplished with a hacksaw or cutting wheel, how-
ever use of a band saw, if available, will greatly speed the process. After cutting clean all rough edges with a file and sand paper.
After trimming, test fit front fascia for proper fit. Trim additional material as needed.
• When satisfied with fit of front fascia, secure plastic substructure to bumper reinforcing bar using factory bolts that were used
to secure front fascia to bumper reinforcing bar. (see Fig. 12.1).
• Using masking tape, temporarily secure styrofoam impact grid in position to plastic substructure.
Figure 12.1 Plastic Substructure and Styrofoam Impact Strip
Styrofoam
Impact Strip
Plastic
Substructure Mounting
Bolt
Mounting
Bolt
12.0