BIC S40 User Manual

Installation Manual

Volvo S40 T5 Front Mount
Intercooler System

Volvo S40 T5 Intercooler System / Installation Manual

Contents

C

Important Information i

Parts List i

Required Tools and Materials 1

1.0 - Vehicle Preparation 1

2.0 - Removing and Trimming Front Fascia (Nose Section) 2

3.0 - Removing Factory Intercoolers and Tubes 3

4.0 - Installing New Intercooler 4

5.0 - Start Engine and Check Connections 6

6.0 - Trim and Install Front Fascia (Nose Section) 7

7.0 - Test Drive 8

!

Important Information

i

Congratulations on your purchase of the Bell Intercoolers Volvo S40 Front Mount Intercooler System. The installation instructions
in this manual will assist you in the complete process of installing your new intercooler. Please read through these instructions
entirely before you begin the installation process. This will familiarize you with the process and alert you to any unique tools or
materials that may be required for successful installation.

however, it is important to honestly evaluate your mechanical skills and determine if you are capable of performing the installation
or if you should have the system installed by a professional mechanic.

A modern internal combustion engine is a precise piece of equipment and while durable they can be severely damaged or de­stroyed through careless installation techniques.

To
problems with the engine or vehicle corrected prior to installing the intercooler.

Parts List

Part Name Packet/Box Qty

Intercooler Assembly -- 1

M8 - 1.25 x 60mm Bolt - Hex Head Parts - Bag 1 2

M8 Flat Washer Parts - Bag 1 2

M5 - 0.8 x 20mm Bolt - Hex Head Parts - Bag 1 1

M5 Flat Washer Parts - Bag 1 1

Hose Clamp - T-Bolt 2.5” Parts - Bag 2 2

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Volvo S40 T5 Intercooler System / Installation Manual

Required Tools and Materials

To effici
supplied with your intercooler.

Tools

• 1/4” Drive Ratchet • T20 and T30 Torx Bits and Suitable Driver

• 1/4” Drive Extensions - 3” Length • Small Flat-head Screwdriver

• 3/8” Drive Ratchet • Phillips Screwdriver

• 3/8” Drive Extension - 3” Length • Hacksaw or Cutting Wheel

• Sockets 8 - 17 mm (1/4” or 3/8” Drive) • Round and Flat File (optional)

• 11 mm Deep Socket • Vehicle Jack or Lift

• Wrenches (Open/Boxed) 8 - 17 mm • Jack Stands (x2)

• Straight Edge Ruler

Materials

• WD-40, Motor Oil or Lubricant • Grease Pencil or China Marker (non-permanent)

1

1.0

As with any vehicle modification project, the process will be easier, faster and safer for the engine, turbocharger and you if the en­gine compartment is thoroughly cleaned before you begin the project. Not only is a dirty engine compartment a mess to work in, but
a dirty engine compartment also offers the possibility that dirt and/or debris could be introduced into the intake tract of the engine.

A small stone or piece of debris falling into an open inlet tube can cause serious and expensive damage when the engine is
started, possibly damaging valves, cylinders and pistons. An easily avoidable, but expensive proposition.

While performing the installation keep the any open intake tubes (air
intake, etc.) covered with a clean rag and thoroughly check all tubes,
hoses and the intercooler for any foreign objects or debris before
installing.

1.1 Disconnect Battery

As a matter of safety you should disconnect the negative battery
terminal before beginning any work on this installation. This is done
to prevent any unintentional shorting of electrical components and to
remove the danger of accidentally energizing the starter motor with
a tool.

The battery is located in the right rear corner of the engine and is
covered.

• Locate battery and remove cover (Fig. 1.1). To remove cover
pull out on sides and lift front.

• Disconnect the negative terminal (Fig. 1.2) and move battery
cable away from negative post.

Vehicle Preparations

Battery
Cover

Figure 1.1

1.2 Jack Stands or Lift

Installation of this intercooler system can be accomplished
without placing the vehicle on a lift or jack stands. However,
you will find the installation process much easier with the car
elevated. If you will be lifting the car please consult Volvo ser­vice manual proper jack, jack stand and/or lift placement. Be
sure vehicle is securely positioned before proceeding.

Negative
Terminal

Figure 1.2

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Volvo S40 T5 Intercooler System / Installation Manual

2

2.0

The first step in the installation will involve removal of the front fascia
(front nose section) of the vehicle (see 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, if so
equipped. 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.

In addition to the front fascia there is a plastic lower panel and a
plastic splash guard (see Fig. 2.2). The plastic lower panel does not
need to be detached from the front fascia for this process. Figure 2.2
shows the lower panel detached for instructional purposes only. The
splash guard is a separate plastic panel positioned underneath the
engine and it must be removed for installation.

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 removing the front fascia.

2.1 Remove Headlight Washer Covers (If so equipped)

There are two headlight washer covers, one per side, that will need
to be removed. This is actually the trickiest part of the entire instal­lation process though it only requires patience and some time to get
the covers off. It may be helpful to have someone to hold the covers
in their extended position to allow you to see the clip mechanism that
secures the covers.

• Carefully pull headlight washer covers away from the bodywork.
These covers are attached directly to the headlight washer mecha­nism, be careful not to twist or damage washer mechanism.

• Insert a small screwdriver into the clip on the underside of the
cover to release clip.

• Remove cover.

• Repeat for opposite washer assembly.

Removing Front Fascia (Nose Section)

Front
Fascia

Lower
Panel

Front
Fascia

Figure 2.1

Splash
Guard

Figure 2.2

2.2 Splash Guard

• Locate and remove the seven (7) T30 Torx fasteners securing the splash guard.

• Remove splash guard.

2.3 Remove Front Fascia Fasteners

• The front fascia is secured by fasteners, plastic rivets and clips in the following locations:

Passenger Fender Well Fasteners (x5)
Driver Fender Well Fasteners (x5)
Upper Radiator Bulkhead (across top) Fasteners (x2), Plastic Rivets (x5)
Lower Radiator Support (across bottom) Clips (x3)

• Using the T20 and T30 Torx bits remove the five (5) fasteners securing the front fascia in
each fender well (see Fig. 2.3).

• Using the T20 Torx bit remove the two (2) fasteners from the upper radiator bulkhead
(see Fig. 2.4).

• Carefully remove the five (5) plastic rivets securing the front fascia to the upper radiator
bulkhead (see Fig. 2.4). Please note, these rivets are designed to be reused. Using a
Phillips screwdriver press the center section of the rivet down approximately 1/8”, until

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1

2

3

4

5

Figure 2.3

Volvo S40 T5 Intercooler System / Installation Manual

you feel a click, when the rivet has released. Once released, you
may extract the rivet from the hole. Repeat for all rivets.

• The lower portion of the front fascia/lower panel assembly is
secured by three plastic tabs inserted into the metal lower radiator
support. Using a screwdriver carefully release these tabs and pull
the fascia assembly forward to disengage. The front fascia is now
ready to be removed.

2.4 Remove Fascia

• Starting at the upper rear corners of the front fascia, pull fascia
away from fender to release.

• Pull out the lower rear corners of the fascia to clear the lower edge
of the fender liners. Repeat for other side.

• At upper radiator bulkhead, pull fascia forward to disengage from
fenders.

• Working evenly across fascia begin to pull fascia forward, away
from vehicle. Remember that you will need to disconnect the driv­ing lights when the fascia does come free of the vehicle.

• Disconnect driving light harnesses, one per side, and remove front
fascia (see Fig. 2.5).

3

Upper Radiator

Bulkhead

Figure 2.4

Driving Light

Assembly

Harness

Connector

Location

3.0

Removing Factory Intercooler

The S40 T5 utilizes a single intercooler design. The intercooler is
secured to the radiator assembly by two (2) T30 mounting bolts.

3.1 Remove Intercooler Air Guide

• In front of the intercooler is the intercooler air guide (see Fig. 3.1).
This plastic piece is attached to the radiator assembly two (2)
fasteners and three (3) plastic tabs.

• Locate and remove the two (2) T30 fasteners securing the inter­cooler air guide to the radiator assembly. These are located at the
upper corners of the intercooler air guide.

• Release three (3) tabs securing the bottom of the air guide to the
radiator assembly (see Fig. 3.1).

• Carefully remove intercooler air guide.

3.2 Remove Intercooler Inlet and Outlet Hoses

• Locate the intercooler inlet hose. This hose is located on the left
side (viewed from front of vehicle) of the intercooler (see Fig. 3.2).

• Loosen hose clamp securing intercooler inlet hose to intercooler
and disconnect hose from intercooler.

• Locate the intercooler outlet hose. This hose is located on the right
side (viewed from front of vehicle) of the intercooler (see Fig. 3.3).

• Loosen hose clamp securing intercooler outlet hose to intercooler
and disconnect hose from intercooler.

Intercooler

Inlet Hose

Figure 2.5

Intercooler

Air Guide

Mounting

Tabs

Figure 3.1

IAT Sensor

Harness

Figure 3.2

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Volvo S40 T5 Intercooler System / Installation Manual

3.3 Remove Hose Clamps

The factory hose clamps will be replaced with high-strength T-bolt
hose clamps for use with your new intercooler. You will need to re­move the factory hose clamps prior to installing the new intercooler.

• Carefully remove factory hose clamps from intercooler inlet and
outlet hoses. These clamps are secured by a small metal barb
that grips the rubber hose. To release the barb carefully pry barb
away from hose. Once the barb is clear of the hose you may safely
remove the hose clamp.

3.4 Disconnect Intake Air Temperature (IAT) Sensor Harness

• Locate wiring harness connected to Intake Air Temperature (IAT)
sensor (see Fig. 3.2).

• Disconnect wiring harness from IAT sensor.

3.5 Remove Intercooler

• Locate and remove the two (2) T30 Torx fasteners securing the
intercooler to the radiator assembly, one fastener per left and right
side (see Fig. 3.3).

• Intercooler is positioned with two plastic tabs at the lower corners.
Lift intercooler to disengage these tabs and remove intercooler.

3.6 Remove IAT Sensor

• Locate the IAT sensor on intercooler (see Fig. 3.4).

• Remove the one (1) T20 Torx fastener securing IAT sensor to inter­cooler.

• Carefully remove IAT sensor from intercooler. The sensor uses an
o-ring, use care when removing the sensor so as not to damage
the o-ring.

4

Mounting
Bolt

Figure 3.3

IAT

Sensor

Figure 3.4

3.7 Remove Crossmember Mounting Bolts

Your new intercooler will be mounted using the front two (2) bolts
securing the radiator lower crossmember (See Figs. 3.5 and 3.6).

• Locate and remove indicated fasteners (see Figs. 3.5 and 3.6).

4.0

Installing New Intercooler

New Components
Intercooler Assembly (x1)

M5 - 0.8 x 20mm Bolt - Hex Head (x1)
M8 - 1.25 x 60mm Bolt - Hex Head (x2)
M5 Flat Washer (x1)
M8 Flat Washer (x2)
Hose Clamp - T-Bolt 2.5” (x2)

4.1 Install IAT Sensor

Prior to installing the new intercooler you will need to install the fac­tory IAT sensor. This sensor installs in the same general position as
the on the factory intercooler. Refer to Figure 4.1 to ensure proper
orientation of the sensor relative to the intercooler.

Left Front

Crossmember

Mounting

Bolt

Figure 3.5

Right Front

Crossmember

Mounting

Bolt

Figure 3.6

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Volvo S40 T5 Intercooler System / Installation Manual

• Apply a thin coating of motor oil to the IAT sensor o-ring.

• Carefully insert sensor into new intercooler. Position as shown in
Figure 4.1.

• Install M5- 0.8 x 20mm bolt and M5 washer (supplied with inter­cooler kit) to secure fastener. Tighten fastener.

4.2 Install T-Bolt Hose Clamps

The T-Bolt hose clamps must be installed prior to installing the inter­cooler. Refer to Figures 4.2 and 4.3 for proper orientation of clamps
to allow for correct clearance of the clamp bolts after installation.

• Position hose clamps on intercooler inlet and outlet hoses. Do not
tighten.

4.3 Install Intercooler

The new intercooler will mount using new fasteners supplied with
the kit. These fasteners will install in place of the factory fasteners
securing the lower radiator crossmember that you removed in step

3.7. Be aware that you will be reconnecting the IAT sensor harness to

the intercooler after installation. Place wiring harness so it does not
become trapped or restricted during installation of intercooler.

• Move intercooler into position with mounting brackets located as
shown in Figures 4.4 and 4.5. Be sure hose clamps are in position
as described in step 4.2.

• Installed M8 - 1.25 x 60mm bolt and M8 washer at each mounting
point. Do not tighten fasteners.

• Position intercooler so there is a consistent gap of approximately
1/8” between the intercooler and the radiator assembly (see Fig.

4.6). When this gap is established, tighten mounting fasteners.

4.4 Reconnect IAT Sensor Wiring Harness

• Reconnect wiring harness to IAT sensor. Check to be sure wiring
harness is not restricted, kinked or pinched by intercooler. Adjust if
necessary.

5

IAT

Sensor

Figure 4.1

Hose

Clamp

4.5 Install Intercooler Inlet and Outlet Hoses

For proper installation the hose clamps must be positioned behind
the hose bead as shown in Figure 4.7. Before installation of intercool­er hoses mark all intercooler tubes with a line 1” in from the bead, as
shown in Figure 4.7. This will allow you be sure the clamp and hose
are properly positioned. There should be approximately 1/8” between
the edge of the hose and the edge of the clamp when installed.

Hose clamps should be tightened to the point where the hose cannot
be rotated against the metal tube. Overtightening can result in cutting
and damaging the hose.

• Slide intercooler inlet and outlet hoses onto intercooler.

• Position and tighten T-bolt hose clamps. Clamps should be posi­tioned as shown in Figures 4.2 and 4.3. Be sure that the clamp
bolts do not contact any surrounding components. Adjust as
necessary.

Figure 4.2

Hose

Clamp

Figure 4.3

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Volvo S40 T5 Intercooler System / Installation Manual

4.6 Recheck All Fasteners, Hose Clamps and Connections

Before proceeding, recheck all hose clamps for proper installation and clearance. Also recheck intercooler position (as per step

4.3) and all mounting fasteners. Recheck IAT sensor harness to be sure it is properly connected.

6

Left-Side Mounting Point

Intercooler

Mounting

Point

Figure 4.5 Figure 4.6

Right-Side Mounting Point

Intercooler

Mounting

Point

Intercooler

Hose

Intercooler

To Radiator

Gap

Figure 4.4

1”

Retaining

Bead

Hose and Clamp Placement Diagram

Hose

Clamp

Intercooler

Tube

Mark

Line

Figure 4.7

5.0

Start Engine and Check Connections

Be
check engine operation and make sure all components are functioning properly. The car will be started, but not be driven at this
time, to determine that all components have been connected properly. Do not start car while on jack stands.

• Remove car from jack stands or lift.

• Reconnect battery.

• Start engine and allow engine to warm to operating temperature.

• Engine should idle and rev normally. If it does not, shut off engine and check for loose intercooler hose connections and dis­connected IAT sensor wiring harness. Restart engine and check for normal idle and revs.

• Shut off engine and disconnect battery.

• Place car back on jack stands or lift to complete installation of front fascia bodywork.

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Volvo S40 T5 Intercooler System / Installation Manual

7

6.0

Trim and Install Front Fascia (Nose Section)

This step requires relatively easy trimming of the plastic and urethane components of the front fascia. All trimming can be easily
accomplished with a hacksaw or cutting wheel and cleaned up with a file and sand paper.

6.1 Remove Lower Grill Insert

The

6.2 Mark Lower Grill Opening

To provide adequate room for the new
intercooler it is necessary to trim the back
of the lower grill opening.

• At each corner of bottom surface mark
a line 1 5/8” from back edge (see Fig.

6.1).

Upper

Cut Line

(Upper Corner)

Mark 3/4”

From Back Edge

(Upper Corner)

Mark 3/4”

From Back Edge

• At each corner of top surface mark a
line 3/4” from back edge (see Fig. 6.1).

• Using a straight edge, mark line across
bottom surface connecting corner marks

(Lower Corner)

Mark 1 5/8”

From Back Edge

(see Fig. 6.1).

• Repeat for top surface (see Fig. 6.1).

• Draw lines on side surfaces connecting
upper and lower corners (see Fig. 6.1).

• Using hacksaw or cutting wheel, care-

(Lower Corner)

Mark 1 5/8”

From Back Edge

Bottom

Cut Line

Figure 6.1

fully cut along lines.

• Carefully clean up cut edges with file
and/or sandpaper. The finished cut can
be seen in Figure 6.2.

6.3 Reinstall Front Fascia

Reinstall front fascia in reverse sequence
of removal process (see Step 2.0, pg 2).

• Position front fascia in front of car and
connect driving light wiring connectors.

• Lift fascia and guide into position.

• Guide tabs below headlights into posi­tion.

• Guide upper fender tabs into position
at each corner of the upper radiator
bulkhead.

• Guide lower corners of fascia over
fender liners (one per side).

• Gently press fascia into position.

• Guide three mounting tabs into position
along lower radiator support.

• Check fascia for proper fit and align­ment against fenders and headlights.
Adjust as necessary.

Trimmed Lower Grill Opening

Trimmed Fascia Installed

Figure 6.2

Figure 6.3

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Volvo S40 T5 Intercooler System / Installation Manual

• Reinstall plastic rivets and fasteners across upper radiator bulkhead.

• Reinstall headlight washer covers (if so equipped).

• When installed, there should be a 1/8” - 1/4” gap between the intercooler surface and the back of the lower grill opening (see
Fig. 6.3).

6.4 Reinstall Splash Guard

Reinstall splash guard in reverse sequence of removal process (see Step 2.2, pg 2).

• Reinstall and tighten seven (7) T30 Torx fasteners securing splash guard.

8

7.0

Testing should be done with the radio and AC/heat fan off and with all windows rolled up to allow you to properly hear the engine.
Allow engine to reach operating temperature and make certain the engine is running smoothly and normally, both at idle and
under load, prior to applying boost.

It
position. This is also the time to check for any potential clearance issues.

Installation is now complete.

Test Drive and System Checks

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