BIC Volvo S60R Front Mount Intercooler System - Manual (Page 23)

Volvo S60R Intercooler System / Installation Manual 21
Bell Intercoolers, inc. © 2009 All rights reserved. S601-S60R-IMv3
• Identify tab indicated in Figure 13.7.
• Cut off tab and clean up cut edge with file and sandpaper.
• Reinstall driving light insert into front fascia.
13.4 Trim Underbody Tray
To provide space for the intercooler inlet tube it is necessary to trim a
portion of the underbody tray in the area behind the left side (passenger
side for US/Canada market cars) as shown in Figure 13.8a.
• Using grease pencil, draw cut lines on underbody tray (see Fig. 13.8b).
• Using hacksaw or cutting wheel, carefully cut along lines.
• Clean up cut edges with file and sandpaper.
13.5 Reinstall Underbody Tray
• Reinstall underbody tray in reverse sequence of removal.
• Insert right side tab into slot below bumper.
• Secure rear mounting points with bolts.
13.6 Reinstall Front Fascia
Reinstall front fascia in reverse sequence of removal process (see Step
2.0, pg 3).
• Reinstall fog lights support brackets on front fascia (one per side).
• Position front fascia in front of car and connect driving light wiring
connectors.
• Lift fascia and guide into position. Be sure to feed headlight washer
tubes through headlight wiper openings.
• The upper corners of the fascia, at the fender, must be guided into
small retaining grooves. Fascia should be flush with fender.
• Position rear edges of fascia on securing clips (see Fig. 2.5).
• Tighten securing clips at each rear edge (Torx T25 fastener).
• Install front mounting bolts and tighten.
• Install six plastic rivets across radiator bulkhead.
• Install headlight wipers and connect washer tubes.
Figure 13.6c Figure 13.6b Figure 13.6a
Cut Lines
Figure 13.8a
Figure 13.8b
Cut Line
Tab to be
Removed
Figure 13.7 Driving Light Insert (Left)