BIC Volvo S60R Front Mount Intercooler System - Manual (Page 6)

Volvo S60R Intercooler System / Installation Manual 4
Bell Intercoolers, inc. © 2009 All rights reserved. S601-S60R-IMv3
2.6 Remove Front Fascia
Note: This process can be accomplished by a single person if you know
what to expect and proceed carefully. That said, it is much easier and
safer for the paint work if you have an assistant.
• Grasping the rear edge of the front fascia (at the wheel opening), gently
pull the fascia out, to the side, approximately .5”, to clear side clips, and
move fascia forward about two inches. Repeat for other side.
• With the front fascia pulled forward slightly you will need to disconnect
the two wiring connectors for the driving lights (one per side). These
are located on the inside of the front fascia, above the left and right side
driving light assemblies. Disconnect both harnesses.
• You may now completely remove the front fascia.
2.7 Remove Underbody Tray
Located underneath the radiator / AC condenser / intercooler assembly is
the underbody tray. It is secured by two bolts (one per side) and two tabs
(one per side). Locate the two tabs on the lower edge of the bumper cross
member, release the tabs and slide them out of their slots. Locate and
remove the two bolts, found at the outer rear corners of the underbody tray.
The underbody tray may now be removed.
Removing Bumper Reinforcing Bar
Note: The installation of the bumper reinforcing bar spacers is not a permanent modification to the vehicle and the bumper rein-
forcing bar can be returned to it’s original position with the use of Volvo standard replacement parts.
The bumper reinforcing bar is the large, aluminum cross bar shown in Figure. 3.1. For installation of the intercooler system you will
be placing spacers between the bumper reinforcing bar and the main vehicle frame. These spacers move the bumper reinforcing
bar forward to allow space for the intercooler.
To remove the bumper reinforcing bar you will remove four bolts (two per
side) and drill out six spot welds (three per side). These bolts and spot
welds are attached to the bumper reinforcing bar via replaceable steel
pads available from Volvo. The spots welds, once drilled out, are replaced
with high strength bolts and the spacers are CNC machined from 6061-T6
aluminum for strength and precision.
Drilling out the spot welds is easily accomplished with a .420” drill bit,
though it is important to start the drill bit in the center of the spot weld to
ensure the weld is completely removed.
Prior to removing the bumper reinforcing bar you will need to drill out the
mounting holes for the new intercooler and radiator bulkhead spacers.
3.1 Enlarge Intercooler Mounting Bracket Holes
The intercooler mounts to the bumper reinforcing bar
and radiator bulkhead with two bolts and spacers. In
addition to the bolts and spacers for the intercooler
• Locate the mounting hole to be used for new
intercooler mounting brackets. These are located
on either side of the upper grill opening and are at-
tached to a flange at the back of the bumper cross
member (as shown in Figures 3.2, 3.3 and 3.4).
Figure 2.5
Securing
Clip
T25
Torx
Fascia
Rear
Edge
Figure 3.1
Bumper
Reinforcing Bar
3.0
Figure 3.2
Mounting Pin
and Hole
Left Side Figure 3.3 Left Side - Detail
Mounting
Pin
Mounting
Hole