BIC Volvo S60R Front Mount Intercooler System - Manual (Page 22)

Volvo S60R Intercooler System / Installation Manual 20
Bell Intercoolers, inc. © 2009 All rights reserved. S601-S60R-IMv3
Trim and Install Front Fascia (Nose Section)
This step requires relatively easy trimming of the plastic and urethane components of the front fascia and underbody tray. All trim-
ming can be easily accomplished with a hacksaw or cutting wheel and cleaned up with a file and sand paper.
You may also use a heated carpet knife to trim some of the urethane components (lower grill opening and driving light area). This
method provides a very clean cut through the urethane and requires no additional finishing to the part. Please note, given the
This
fascia urethane.
13.1 Trim Lower Grill Opening
To provide adequate room for the new intercooler it is necessary to trim
the back of the lower grill opening (see Fig. 13.3). Volvo has provided a
convenient trimming line in the form of the edge of the painted surface
in this area (see Fig. 13.2a). You will be applying a strip of masking tape
along this paint line to protect the paint and provide a cutting guide.
Overlap tape onto unpainted surface by approximately 1/8”. This will
prevent you from cutting through the painted surface and will prevent
paint from chipping during the cutting process.
• Identify paint line on lower grill area (see Fig. 13.4a).
• Apply masking tape to the painted side of this line, covering painted
surface (see Fig. 13.4b).
• Using hacksaw, cutting wheel or heated knife, carefully cut along line.
• Clean up cut edge with file and sandpaper. The finished cut can be
seen in Figure 13.4c.
13.2 Trim Left Driving Light Area
To provide space for the intercooler inlet tube it is necessary to trim a
portion of the front fascia in the area behind the left side (passenger
side for US/Canada market cars) as shown in Figures 13.5 and 13.6a.
• Using grease pencil draw cut lines on front fascia as shown in Figure
13.6b.
• Using hacksaw or cutting wheel, carefully cut along lines.
• Clean up cut edges with file and sandpaper.
• Finished cut can be seen in Figure 13.6c.
13.3 Trim Left Driving Light Grill Tab
• Remove driving light insert from left side front fascia (passenger side
for US/Canada market cars).
!
13.0
Figure 13.3
Area to be
removed
Figure 13.4c Figure 13.4b Figure 13.4a
Paint Line
Figure 13.5
Area to be
Trimmed