BIC Volvo S60R Front Mount Intercooler System - Manual (Page 5)

Volvo S60R Intercooler System / Installation Manual 3
Bell Intercoolers, inc. © 2009 All rights reserved. S601-S60R-IMv3
Removing Front Fascia (Nose Section)
Note: Before beginning any work on the vehicle the battery must be
disconnected. See page 1 for details.
The first step in the installation will involve removal of the front nose
section or fascia of the vehicle (Fig. 2.1). Attached to the front fascia
are: the upper grill assembly, the front license plate and mounting
bracket, the driving light assemblies and driving light grills. All of
these pieces remain attached to the front fascia when it is removed
and only require that you disconnect one wiring connector for each
driving light assembly, one per side.
To reduce the chance of damaging the vehicle paint on the front
fascia and the surrounding bodywork, we recommend you have
someone available to help when you remove the fascia.
2.1 Remove Headlight Wipers
Before removing wipers make a note of the position of the wipers
(direction of arms) so you will reinstall them properly. Next fold the
wiper arm forward to access and remove the washer fluid tubing.
• Using small screwdriver, flip up cover at base of wiper arm (Fig.
2.2). Remove the 8 mm nut securing wiper arm. With the nut
removed, carefully grip the base of the wiper arm with locking
pliers as shown (Fig. 2.3). While gently rocking the wiper arm up
and down, pull the wiper arm off of the shaft being careful to not
damage the paint. You may want to wrap the locking pliers in a rag
to prevent paint damage.
• Repeat for opposite side wiper assembly.
2.2 Remove Trim Pieces
Two trim pieces (shown in Fig. 2.1), one per side, are held in place by tabs along the
top and bottom of each piece, which are inserted into the front fascia.
• Start at the front of the trim piece (end closest to upper grill opening). Along the lower
edge of the trim piece, approximately 1.5” from front/inner end of piece, carefully
insert the edge of the trim/molding removal tool (or butter knife) under the trim piece
as shown (Fig. 2.4). Gently pry the trim piece away from the front fascia to release
mounting tab. Once the first tabs has been released you will be able to easily release
the rest of the tabs by hand.
• Repeat for opposite side trim piece.
2.3 Remove Mounting Bolts
• Locate the two bolts securing the front fascia assembly to the bumper subframe (one per side as indicated in Fig. 2.1). Re-
move these bolts, using care not to allow the bolts to drop into the space in the front fascia assembly.
2.4 Loosen Retainers
• Using the T25 Torx bit, loosen the two retainer fasteners, one on each side of the front fascia. They are located just inside the
wheel opening on the fender liner (one per side as indicated in Fig. 2.1) and secure the fascia with a small clip. The fastener
Fig. 2.5 for a detail of this clip.
2.5 Remove Bulkhead Rivets
• Loc
bulkhead. Please note, these rivets are designed to be reused. Using a Phillips screwdriver press the center section of the
ri
Repeat for all rivets.
2.0
Figure 2.1
Figure 2.2 Figure 2.3
Figure 2.4
Trim Piece
Bolt Location
(under trim) T25 Torx
Location