BIC Volvo S60R Front Mount Intercooler System - Manual (Page 7)

Volvo S60R Intercooler System / Installation Manual 5
Bell Intercoolers, inc. © 2009 All rights reserved. S601-S60R-IMv3
• Using the .420” drill bit, enlarge each of the two mounting holes. The
holes are only approximately .25” deep, only drill deep enough to
properly enlarge the holes to prevent damage to radiator.
• Remove mounting pins from each side.
• Using the .312” drill bit, enlarge the mounting pin holes in both the
bumper reinforcing bar and the radiator bulkhead.
3.2 Remove Bumper Reinforcing Bar
• Remove secondary nuts from back of outer bolts, one per side (see
Fig. 3.5). These are not the main nuts which are permanently attached
to the back of the bumper reinforcing bar, but are used to secure
electronic components (these secondary nuts may not be pres-
ent on all models). These nuts must be removed before the bolt is
removed to avoid damaging the nut and bolt.
• Remove outer bolts, one per side (see Fig. 3.5).
• Drill out spot welds. To center the drill on the spot welds, use
a punch or similar tool to indent the center of each spot weld.
It is important to center the drill bit in each spot weld so that
the weld is fully removed. Using .420” drill bit drill out the six
spots welds securing bumper reinforcing bar (three per side as
shown in Fig. 3.5).
• Support bumper reinforcing bar and remove inner bolts, one per
side (see Fig. 3.5).
• Remove bumper reinforcing bar. It will be necessary to rotate the
bottom of the bumper bar forward to clear radiator bulkhead
mounting point. If bar does not immediately come loose from the
main frame supports you may need to insert a suitable tool (pry
bar, large screw driver) to gently pry it loose. If the bumper rein-
forcing bar does not come free with reasonable force check to be
sure all bolts have been removed and that all spot welds are fully
drilled out (if spot welds are drilled off center the welds may still
be partially intact).
Removing Air Filter Assembly
4.1 Remove Cold Air Snorkel
• Locate and remove the two bolts securing cold air snorkel to air
filter box (Items A in Fig 4.1). Locate and remove the three bolts
securing cold air snorkel to radiator bulkhead (Items B in Fig 4.1).
• Remove cold air snorkel from air filter box, you may need to
release the two small raised tabs located next to the A bolts.
• Slide cold air snorkel out of radiator bulkhead.
4.2 Remove Air Filter Assembly
• Locate and loosen hose clamp securing air inlet tube to air filter
box (Fig 4.2). Unclip and disconnect mass air sensor from air filter
box (Fig 4.2).
• Locate and remove the three bolts securing the air filter box. Two
bolts located to the left side of the box and one to the right.
4.0
Figure 4.1
Air Filter Box
Cold Air
Snorkel
A
B
Air Inlet
Tube
Figure 3.6
Replacable
Steel Pad
Spot Weld
Bolt
Mounting
Hole
Center of
Spot Weld
Figure 3.4
Radiator
Bulkhead
Mounting Bolt
Mounting
Pin
Bumper
Reinforcing
Bar
Right Side Detail
Figure 3.5
Inner
Mounting
Bolt
Outer
Mounting
Bolt
Inner
Spot Weld
Outer
Spot Welds
(x2)