BIC S60R User Manual

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Installation Manual

Volvo S60R Front Mount Intercooler System

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Volvo S60R Intercooler System / Installation Manual

Contents

Important Information 1

Parts List 1

Required Tools and Materials 2

1.0 Vehicle Preparation 2

2.0 Removing Front Fascia (Nose Section) 3

3.0 Removing Bumper Reinforcing Bar 4

4.0 Removing Air Filter Assembly 5

5.0 Removing Factory Intercoolers and Tubes 6

6.0 Drilling, Trimming and Misc. 9

7.0 Installing New Intercooler 10

8.0 Installing New Intercooler Tubes 12

9.0 Reinstalling Bumper Reinforcing Bar and Spacers 12

10.0 Reinstalling Air Filter Assembly 15

11.0 Start Engine and Check Connections 15

12.0 Trim and Install Front Fascia (Nose Section) Substructure 16

13.0 Trim and Install Front Fascia (Nose Section) 20

14.0 Test Drive 22

Important Information

Congratulations on your purchase of the Bell Intercoolers Volvo S60R 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 m please do not hesitate to contact us at 210-412-0917.

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. To help you identify possible difﬁculties, we have marked steps of installation that are complex, require special tools or involve special procedures with this icon:

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.

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Volvo S60R Intercooler System / Installation Manual

Parts List

Part Name Packet/Box Qty Part Number

Intercooler Assembly Intercooler 1 A3001361806070(B)

Intercooler Mounting

Intercooler Mounting Spacer Parts - Bag 1 2 PLV6070-12

M10-1.25 x 80mm Bolt - Hex Head Parts - Bag 1 2 P00700-M10-80-Z

M10 Washer Parts - Bag 1 4 P00740-M10-C

M10-1.25 Hex Nut (Mechanical Locknut) Parts - Bag 1 2 P00710-M10-15-Z

Intercooler Tubes

Intercooler Inlet Tube Components 1 PLV6070-01-B

Intercooler Outlet Tube Components 1 PLV6070-02-B

Throttle Inlet Tube Components 1 PLV6070-03-B

Silicone Hose

Straight (2.5” ID x 3.0” L) Hoses 1 P00503-0300BLAC

Straight Bellows Type (2.5” ID x 3.0” L) Hoses 2 P00553-0300BLAC

Straight (3.0” ID x 2.5” L) Hoses 1 P00505-0300BLAC

Reducer (2.0” or 2.25” to 2.5” ID x 3.0” L) Hoses 1 P00562-250200B or P00561-250225B

Poly Wire Loom - .75” Dia. x 14” L Components 1 00760

Hose Clamps - T-Bolt Style

2.25” or 2.0” (Hose ID) Hose Clamps 1 P00600-002 or P00607-002

2.5” (Hose ID) Hose Clamps 7 P00603-002

3.0” (Hose ID) Hose Clamps 2 P00609-002

Horn Brackets and Fasteners

Horn Bracket - Left Parts - Bag 2 1 PLV6070-05

Horn Bracket - Right Parts - Bag 2 1 PLV6070-06

M6-1.0 x 20mm Bolt - Hex Head Parts - Bag 2 2 P00700-M6-20-Z

M6-1.0 Hex Nut (Mechanical Locknut) Parts - Bag 2 2 P00710-M6-1.0-Z

M6 Washer Parts - Bag 2 4 P00740-M6-C

Radiator/AC Condenser Spacer and Fasteners

Radiator/AC Condenser Spacer Parts - Bag 3 4 PLV6070-08

M6-1.0 x 40mm Bolt - Hex Head Parts - Bag 3 4 P00700-M6-40-Z

M6 Washer Parts - Bag 3 5 P00740-M6-C

M6-1.0 x 20mm Bolt - Hex Head (IAT Sensor) Parts - Bag 3 1 P00700-M6-20-Z

Bumper Bar Spacers and Fasteners

Bumper Spacer - Outer Parts - Bag 4 2 PLV6070-14

Bumper Spacer - Inner Parts - Bag 4 2 PLV6070-15

Radiator Bulkhead Spacer Parts - Bag 4 4 PLV6070-13

M10-1.5 x 60mm Bolt - Hex Head Parts - Bag 5 2 P00700-M10-60-Z

M10 Washer - Canted Parts - Bag 5 4 P00741-M10-CANT

M8-1.25 x 40mm Bolt - Hex Head Parts - Bag 5 6 P00700-M8-40-Z

M8-1.25 Hex Nut (Mechanical Locknut) Parts - Bag 5 6 P00710-M8-1.25

M8 Washer Parts - Bag 5 8 P00740-M8-C

M8 Washer - Canted Parts - Bag 5 4 P00741-M8-CANT

M10-1.5 x 45mm Bolt - Hex Head Parts - Bag 5 2 P00700-M10-45-Z

M10 Washer Parts - Bag 5 4 P00740-M10-C

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Volvo S60R Intercooler System / Installation Manual

Required Tools and Materials

To efﬁci supplied with your intercooler.

Tools

• 1/4” Drive Ratchet • .457” Drill Bit (or next larger size available)

• 1/4” Drive Extensions - 3” and 6” Length • .312-.328” Drill Bit (or next larger size available)

• 3/8” Drive Ratchet • Vise-Grip style locking pliers (2 required)

• 3/8” Drive Extension - 3” Length • Small Trim/Molding Removal Tool (or Butter Knife)

• Sockets 8-17mm (1/4” or 3/8” Drive) • Hacksaw or Cutting Wheel

• 11 mm Deep Socket • Round and Flat File

• Wrench (Open/Boxed) 8-17mm • Ruler – 12” or longer

• T-25 and T-15 Torx Bits • Vehicle Jack or Lift

• Flat-head Screwdriver • Jack Stands (x2)

• Phillips Screwdriver • Carpet Knife (Optional)

• Electric Handheld Drill (capable of holding .5” bit) * Butane or Propane Torch (Optional)

• Drain Pan for Engine Coolant

Materials

• Grease Pencil or China Marker (non-permanent) • Masking Tape

• Black Ink Marker Pen (Sharpie™) • Sandpaper - 600 Grit

• Satin Black Touch Up Paint

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 turbo inlet can cause serious and expensive damage to the turbo when the engine is started. Even worse, the debris could cause a turbocharger compressor failure leading to pieces of compressor blades feeding into the cylinder, possibly damaging valves, cylinders and pistons. An easily avoidable, but expensive proposition.

Wh all tubes, hoses and the intercooler for any foreign objects or debris before installing.

1.1 Disconnect Battery

Before beginning any work on this installation disconnect the negative terminal of the battery. During the installation you will have

ba your Volvo service manual for details and procedures on disconnecting the trunk mounted battery.

1.2 Jack Stands or Lift

Installation of this intercooler system requires placing the vehicle on a lift or jack stands. Please consult Volvo service manual proper jack, jackstand and/or lift placement. Be sure vehicle is securely positioned before proceeding.

Vehicle Preparations

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Volvo S60R Intercooler System / Installation Manual

2.0

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.

T25 Torx Location

Trim Piece

Figure 2.2

Bolt Location

(under trim)

Figure 2.1

Figure 2.3

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

Figure 2.4

• Locate the two bolts securing the front fascia assembly to the bumper subframe (one per side as indicated in Fig. 2.1). Remove 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.

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Volvo S60R Intercooler System / Installation Manual

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.

T25 Torx

Securing

Clip

Fascia

Rear

Edge

Figure 2.5

3.0

Removing Bumper Reinforcing Bar

Note: The installation of the bumper reinforcing bar spacers is not a permanent modiﬁcation to the vehicle and the bumper reinforcing 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.

Bumper

Reinforcing Bar

Figure 3.1

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 attached to a ﬂange at the back of the bumper cross member (as shown in Figures 3.2, 3.3 and 3.4).

Mounting Pin and Hole

Mounting Pin

Mounting Hole

Left Side

Figure 3.2

Left Side - Detail

Figure 3.3

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Volvo S60R Intercooler System / Installation Manual

• 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 present 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 reinforcing 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).

Mounting

Radiator

Bulkhead

Mounting Bolt

Bumper

Reinforcing

Spot Weld

Center of

Spot Weld

Replacable

Steel Pad

Bar

Inner

Mounting

Bolt

Inner

Spot Weld

Right Side Detail

Outer

Mounting

Bolt

Spot Welds

Figure 3.4

Outer

(x2)

Figure 3.5

4.0

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.

Bolt

Mounting

Hole

Figure 3.6

Cold Air Snorkel

Air Inlet Tube

Air Filter Box

Figure 4.1

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Volvo S60R Intercooler System / Installation Manual

• The air ﬁlter box is now ready to be removed. Lift the front of the air ﬁlter box and remove air ﬁlter box from air inlet tube. Once clear of the air inlet tube, lift air ﬁlter box and disconnect vacuum line bundle, located on the driver’s side of the air ﬁlter box. This bundle of vacuum lines is secured to air ﬁlter box with a tab and it can pulled off.

• Remove air ﬁlter box.

5.0

Removing Factory Intercoolers

Air Inlet Tube

Hose Clamp

Mass Air Sensor

Figure 4.2

Note: For this step of the installation process it will be necessary to drain the engine coolant. At this point you may wish to replace your engine coolant, as well as radiator hoses. We recommend replacing hoses if they have been in use for more than two years or 20,000 miles, as they can become less ﬂexible and prone to cracking and failure when handled.

The S60R utilizes two intercoolers, a large primary intercooler and a small secondary intercooler, in the factory intercooler system. The primary intercooler is secured between the AC condenser and radiator to form an assembly which is then attached to the radiator bulkhead. To remove the primary intercooler you must detach the AC condenser and primary intercooler from the radiator. The radiator and AC condenser will be lowered to extract the primary intercooler. The AC system does NOT need to be evacuated form this process, though care must be exercised when working with the various AC lines and components to prevent damage.

5.1 Remove Secondary Intercooler

• Locate the secondary intercooler connection hoses on each end of the secondary intercooler. Loosen all hose clamps (x4) for the left and right connection hoses.

• Locate and remove the two mounting bolts securing the secondary intercooler to the AC condenser (see Items A in Fig. 5.1).

• Remove secondary intercooler and intercooler connection hoses.

Inlet

Hose

Outlet

Tube

Primary

Intercooler

Secondary Intercooler

Factory Intercoolers, Tubes and Hoses

Illustration / Volvo Cars North America

Vacuum/

Boost

Port

IAT

Sensor

Figure 5.1

5.2 Remove Intercooler Inlet Hose and Outlet Tube

• Locate intercooler inlet hose (see Fig. 5.1).

• Loosen hose clamp securing intercooler inlet hose to intercooler.

• Loosen hose clamp securing intercooler inlet hose to the over-engine-pipe (OEP, the large tube running over top of engine from front to rear). Remove intercooler inlet hose.

• Locate vacuum/boost port on intercooler outlet tube (see Fig. 5.1). Remove hose from port.

• Locate and loosen hose clamp securing intercooler outlet tube to intercooler.

• Locate hose clamp securing intercooler outlet tube to underside of engine intake manifold. Loosen hose clamp and remove tube.

5.3 Remove IAT Sensor Harness

• Locate the intake air temperature (IAT) sensor, located on intercooler outlet (see Fig. 5.1). Disconnect wiring harness from IAT sensor. Locate and remove bolt securing IAT sensor to intercooler (T15 Torx bit). Carefully remove IAT sensor being sure not to damage O-ring seal.

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Volvo S60R Intercooler System / Installation Manual

5.4 Drain Engine Coolant

Note: You may wish to replace your engine coolant and radiator hoses as

part of routine maintenance.

• Locate the plastic radiator drain plug/nozzle at the lower right (driver side) corner of the radiator (see Fig. 5.2).

• Remove cap from coolant reservoir in engine compartment.

• Position drain pan and loosen, but do not remove drain plug. Coolant will drain without the drain plug being completely removed.

• When coolant completely drained, retighten coolant drain plug.

5.5 Disconnect Radiator Hoses

• Loosen hose clamps securing upper and lower radiator hoses to radiator.

• Disconnect upper and lower radiator hoses from radiator. Remove hoses completely if replacing with new hoses.

5.6 Remove Cooling Fan Assembly

• Locate and remove two (2) bolts securing cooling fan assembly to radiator. These will be located at the upper corners of the cooling fan assembly.

• Disconnect fan wiring harness.

• Lift fan assembly to disengage two (2) mounting tabs near bottom of fan assembly.

• Carefully lift cooling fan assembly from behind radiator, being sure not to damage radiator cooling ﬁns or core when extracting the fan assembly.

Coolant

Drain Plug

Figure 5.2

Figure 5.3

5.7 Remove Primary Intercooler

Note: The AC condenser, intercooler and radiator are lowered

together (see Fig. 5.3) before removing the intercooler. The AC condenser is not completely removed from the vehicle and the AC lines are NOT disconnected during this process. Care must be given to ensure the AC lines and connections are not damaged during this process.

• Locate wiring connector on AC condenser, on passenger side, attached to AC Dryer (silver canister). Disconnect connector.

• Locate and remove the two (2) bolts securing top of radiator to radiator bulkhead.

• Locate the four bolts connecting the AC condenser, primary intercooler and radiator (see Items A in Fig. 5.4). Remove the two upper connecting bolts. Remove the two lower connecting bolts.

• Locate and remove the two (2) bolts securing the radiator to the vehicle (see Items B in Fig. 5.4). Carefully lower radiator, AC condenser and intercooler into position shown in Fig. 5.3.

• Carefully separate AC condenser and radiator from intercooler and remove intercooler. It will be necessary to extract the intercooler towards the top of the AC condenser and radiator due to the various AC lines. Exercise care to avoid damaging AC condenser and radiator ﬁns during this process.

Radiator/AC Condenser/Intercooler

Radiator

Mounting Points

Illustration / Volvo Cars North America

Figure 5.4

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Volvo S60R Intercooler System / Installation Manual

5.8 Reposition AC Dryer

Note: This step may or may not be required for your

particular vehicle. S60R model years 2004-2005 use a larger AC dryer canister than the later 20062007 models (see Fig. 5.5 and 5.6). If your vehicle is equipped with the smaller AC dryer canister you will not need to perform this step and should skip to Step 5.9.

This step in the installation process requires repositioning the AC dryer (see Figure 5.7) by bending the AC dryer bracket slightly. This procedure does not require any special tools, equipment or techniques. However, the bracket to be bent is attached to the AC condenser and care must be taken not to dam-

Early Style AC Dryer

age the AC condenser during the process. Do not force AC lines during the removal process.

The AC dryer is attached to the AC condenser with an aluminum bracket. This bracket is fairly easy to bend into the new position by rotating the AC dryer as shown in Figure 5.7. The AC dryer will be moved approximately 1” when rotated from it’s original position. The before and after positions of the AC dryer can be seen in Figures 6.8a and 6.8b.

• Grip the AC dryer canister ﬁrmly with both hands or with a large pair of channel lock pliers. Carefully ro-

Rotate

tate AC dryer canister, bending the bracket as shown in Figure 5.7. Only the aluminum bracket should bend within the bracket bend area indicated in Figure 5.7.

When the AC dryer is properly positioned Section A of the bracket will be in line with the face of the AC condenser (see Figures 5.7, 5.8a and 5.8b).

Dryer

Figure 5.5

New

Position

AC Dryer Positions - Bottom View

Dryer

Late Style AC Dryer

Bracket

Bend

Area

Bracket

Section A

Original Position

Figure 5.6

Condenser

Figure 5.7

5.9 Reassemble AC Condenser and Radiator

• Reassemble radiator / AC condenser assembly. At each of the four connecting points position supplied Radiator/AC Condenser Spacer between the radiator and AC condenser and insert supplied bolt and washer assembly into each corner of the radiator /AC condenser assembly (see Figure 5.9, Note: Spacer, normally black, is shown here in silver for photographic clarity).

• On vehicles with larger AC dryer canister check clearance of AC dryer to radiator. There should be no contact between AC dryer and radiator, if there is contact, carefully rotate AC dryer to provide additional clearance (see Step 5.7). There should be at least 1/8” between AC dryer canister and any part of the radiator.

• Tighten four (4) bolts to secure AC condenser to radiator.

• Return AC condenser / radiator assembly to original position and reinstall two (2) bolts securing radiator to vehicle (see Items B in Fig. 5.4). Do not tighten these bolts until after step 6.2. Do not reinstall two (2) bolts securing top of radiator to radiator bulkhead.

Original Position

Bottom View

Figure 5.8a

Spacer

New Position

Bottom View

Figure 5.8b

Figure 5.9

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Volvo S60R Intercooler System / Installation Manual

6.0

Drilling, Trimming and Misc.

6.1 Installing Horn Brackets

Installation of the larger intercooler requires the use of new horn brackets. These brackets rotate the horns from their original vertical position in the upper grill opening to a horizontal position (see Fig. 6.1). The following brackets and fasteners are provided with your intercooler system:

New Components Horn Bracket - Left (x1)

Mounting

Point

Mounting

Point

Horn Bracket - Right (x1) M6-1.0 x 20mm Bolt - Hex Head (x2) M6-1.0 Hex Nut (Mechanical Locknut) (x2) M6 Washer (x4)

• Remove horns and original brackets. Locate and remove

Horn (Left)

Horn (Right)

bolts securing the twin horns in the upper grill opening. Note orientation of horns. The horns are secured with one bolt per horn. Disconnect wiring connector from each horn. Remove horns and label as “Right” and “Left.”

Final Horn Position

Upper Grill Opening

(from front)

Figure 6.1

• Remove factory brackets from each horn. Secured with a single bolt which will be used to attach the new horn brackets.

• The factory horns have a trumpet style shape and the opening of that shape is in close proximity to the top of the new intercooler. This

Bracket

(Left)

Mounting Bolt

Horn

(Left)

proximity can reduce the effective volume level of the horns and we recommend that you trim the horn trumpet slightly to allow for proper horn volume.

Front

Referring to Figure 6.3, trim each horn using a hacksaw.

• Identify new left and right brackets and attach to horns as shown in Figure 6.2 (Left side horn and bracket shown, reverse for right side). Tighten bolts. Note: Left refers to passenger side, right to driver side.

Wiring

Connection

Left Horn/Bracket

Assembly

Figure 6.2

• Place horns into grill opening, behind power steering cooler and install using the supplied nuts, bolts and washers. Note that the horns are now rotated 90º from their original position. Figure 6.1 shows the horns in their new positions (power steering cooler not shown) with mounting bolts for brackets facing up, rather than forward. Note position of wiring connectors, these should face forward. Align horns and tighten.

• Attach wiring connectors to each horn.

Trim Line

6.2 Trim Radiator Bulkhead

Note: This step involves cutting and/or grinding to remove metal from the upper radiator bulkhead. This material is removed the enlarge the opening for the AC charging port. A hacksaw and ﬁle or a Dremel tool with cutting wheel and grinder will accomplish the job with little difﬁculty. However, if you are not comfortable with tackling this job yourself, any good paint and bodyshop will be able to do this for you.

• Locate AC charging port opening in radiator bulkhead. It is located just above the left edge of the upper grill opening, as shown in Figure 6.3 and Figure 6.4b (detail).

• Using a grease pencil draw a line straight back from the edge of the existing hole in the radiator bulkhead (Items A in Figure 6.4b).

• Draw a line across, connecting the two previous lines, 3 inches from the bottom of the opening (Item B in Figure 6.4b).

Trimmed

Figure 6.3

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Volvo S60R Intercooler System / Installation Manual

• Radius each of the upper corners as shown in Figure 6.4b. A .5” radius is shown.

Using a hacksaw or cutting tool, cut carefully along lines. Exercise care to avoid damaging the radiator. Smooth edges with ﬂat and round ﬁles. Figure 6.4c shows the ﬁnished AC charging port opening shape.

• Coat any exposed metal with touch-up paint.

• Properly reposition radiator and AC condenser assembly and tighten two (2) bolts securing top of radiator to radiator bulkhead.

• Tighten two (2) bolts securing radiator to vehicle (see Items B in Fig. 5.4).

• Reinstall upper and lower radiator hoses and reﬁll engine coolant with speciﬁed type and quantity. Close coolant reservoir cap.

AC Charging Port

3”

Figure 6.3

7.0

New Components Bumper Spacer - Outer (x2) M8-1.25 x 40mm Bolt - Hex Head (x6)

Bumper Spacer - Inner (x2) M8-1.25 Hex Nut (Mechanical Locknut) (x6) Radiator Bulkhead Spacer (x4) M8 Washer (x8) M10-1.5 x 60mm Bolt - Hex Head (x2) M8 Washer - Canted (x4) M10 Washer - Canted (x4) M10-1.5 x 45mm Bolt - Hex Head (x2) M10 Washer (x4)

Reinstall Bumper Reinforcing Bar

Figure 6.4a

Figure 6.4b

Figure 6.4c

7.1 Remove Plastic Backing Plate

• Remove plastic backing plate from bumper reinforcing bar. This backing plate is secured with two plastic rivets which can be removed by tapping out the center section. (see Fig. 7.1).

7.2 Adjust Mounting Tabs

• Locate inboard and outboard bumper bar mounting tabs on vehicle frame (see Fig. 7.2). These are the large mounting points that secure the bumper reinforcing bar.

• Using vise-grip type pliers gently bend the outboard tabs forward so they are aligned with front face of AC condenser (see Fig. 7.3). These tabs are easy to bend and the bend does not need to be exact, as the tabs will conform to the angle of the bumper reinforcing bar spacers when tightened.

• Bend inboard tabs back so they are parallel with front face of AC condenser (see Fig. 7.3).

Bumper

Reinforcing

Bar

(back)

Plastic Backing

Plate

Figure 7.1

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Volvo S60R Intercooler System / Installation Manual

7.3 Reinstall Bumper Reinforcing Bar

• Position bumper reinforcing bar and install using inner bumper spacers (one per side) and fasteners (see in Fig. 7.4). Do not tighten. If bolt does not align with hole you may need to adjust frame mounting tabs (see Fig. 7.3)

• Position and install outer bumper spacers and fasteners as shown in ﬁgures 7.4 and 7.7. Do not tighten.

• Position and install outboard radiator bulkhead spacers and fasteners as shown in ﬁgures 7.4 and 7.6. Do not tighten.

• Using intercooler mounting bolts (M10-1.25x80) as guides, position inboard radiator bulkhead spacers.

• Install outboard radiator bulkhead spacers and fasteners (M8-1.25 x 40 bolts, washers and locknuts). Do not tighten.

• Tighten bumper reinforcing bar and radiator bulkhead fasteners in the following sequence (see Figs. 7.4 and 7.5):

1) Inner bumper bolts (one per side)

2) Outer bumper bolts - Center (three per side)

3) Outer bumper bolts - Upper and Lower (two per side)

4) Radiator bulkhead bolts (one per side)

• Remove intercooler mounting bolts that were used as guides from radiator bulkhead mounting point, leaving spacers in place.

Inner Tab

New

Position

Original Position

Mounting Tabs

Front

Figure 7.2

Outer Tab

Original Position

New

Position

M10-1.5 x 45

Inner

Grill Opening

M10-1.25 x 80

Inner Mounting Point

Radiator Bulkhead Mounting Tab Detail

Outer Mounting Point

M8-1.25 x 40

M10-1.5 x 60

M8-1.25 x 40

Headlight

Outer

Figure 7.4

M8-1.25 x 40

Figure 7.5

Inner Spacer

Top View

Mounting Tab Bend

Mounting Tabs

(Frame)

Inner

Spacer

Bumper

Reinforcing

Bar

Canted

Washers

Front

Figure 7.3

Outer

Spacer

Outer Spacer

Top View

Figure 7.7Figure 7.6

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Volvo S60R Intercooler System / Installation Manual

8.0

Installing New Intercooler

New Components AC Condenser / Radiator Spacer (x4)

Intercooler (x1) M10-1.25 x 80mm Bolt - Hex Head (x2) Intercooler Spacer (x2) M10-1.25 Hex Nut (Mechanical Locknut) (x2) M10 Washer (x4)

8.1 Install New Intercooler

The new Intercooler will be installed with the mounting brackets facing forward. When the Intercooler and Intercooler Spacers are installed properly there will be approximately a .5” gap between the Intercooler face and the AC condenser face. The Intercooler should be parallel to the AC condenser.

Pay special attention to the position of the intercooler spacers. Each of the two spacers has an angled face and must be installed with the wide section of the spacer facing down (see Figure 8.2). If these intercooler spacers are not correctly positioned the intercooler will not align with the AC condenser face.

• Move intercooler into position in front of AC condenser. Be careful not to damage cooling ﬁns on Intercooler or AC condenser.

• Install mounting fasteners and spacers through as shown in Figure 8.2. Be sure spacers are rotated as shown, with widest section to the bottom, to ensure proper spacing between the intercooler and AC condenser.

• Align bottom edge of Intercooler to bottom edge of radiator / AC condenser Assembly and tighten mounting fasteners.

• Check for proper alignment and spacing between intercooler and AC condenser (approximately .5”) and parallel mounting to the AC condenser.

Inlet

Bracket

Intercooler

Bracket

Intercooler - Front View

Radiator

Bulkhead

Intercooler

Spacer

Cross Member

Bracket and Fastener Diagram

Radiator Bulkhead

Bumper

Bracket

Outlet

Figure 8.1

Spacer

Figure 8.2

9.0

Installing New Intercooler Tubes

New Components Intercooler Inlet Tube (x1) Poly Wire Loom (x1)

Intercooler Outlet Tube (x1) Silicone Hose - Straight 2.5” Dia. (x1) Throttle Inlet Tube (x1) Silicone Hose - Straight 3.0” Dia. (x1) Hose Clamp (T-Bolt) - 2.0” or 2.25” (x1) Silicone Hose - Bellows 2.5” Dia. (x2) Hose Clamp (T-Bolt) - 2.5” (x7) Silicone Hose - Reducer 2.0” or 2.25” - 2.5” Dia. (x1) Hose Clamp (T-Bolt) - 3.0” (x2)

Note: To ensure the intercooler tubes are securely installed you will need to properly position the silicone hose and hose clamps in f of the tube under high boost pressure.

Fo er tubes mark all tubes with a line 1” in from the bead. This will allow you be sure the clamp and hose are properly positioned.

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

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Volvo S60R Intercooler System / Installation Manual

The hose clamps for the intercooler inlet tube and intercooler outlet tube may positioned as shown in Figures 9.3a, 9.3b, 9.4a, 9.4b and

9.4c to allow for easy access for tightening while not rubbing on the

front fascia bodywork.

9.1 Relocate Wiring Harness

To avoid damage to wiring harness due to close proximity to accessory drive belt and pulley it is necessary to relocate a short portion of the wiring harness. This section of wiring harness is located behind

Intercooler

Inlet Tube

Intercooler

Outlet Tube

Throttle

Inlet Tube

radiator and lower left corner of radiator and runs between the engine and the radiator. To relocate this section you will disconnect the tabs securing the harness, wrap the harness in a poly wire loom (provided with system) and relocate the harness closer to the radiator. Care must be exercised when working with the wiring harness so as not to damage any of the wires.

• Locate wiring harness. Harness is located between the radiator and

engine near lower left corner of radiator. Note position of harness in relation to crossmember and radiator. Harness will be moved

Figure 9.1

forward towards radiator.

• Locate and remove bolt securing wiring harness guide to engine crossmember.

• Separate two halves of wiring guide. Carefully clip zip ties as needed so as not to damage any wires.

• Extract wiring harness from guide to just past securing bolt.

• Using a hacksaw or suitable cutting tool carefully cut wire guide .5” outboard of mounting tab securing guide. Cut both halves of guide. Remove cut section of guide.

• Using electrical tape carefully wrap exposed wiring harness to keep loose wires bundles. Use tie wraps to secure taped bundle every six inches.

• Carefully insert exposed wiring harness into poly wire loom (provided with system). Secure ends of wire loom with tie wraps.

• Reposition fully wrapped wiring harness forward towards radiator. Harness will be held away from accessory drive belt and pulley by intercooler inlet tube.

9.2 Install Intercooler Inlet Tube

• Mark both ends of intercooler inlet tube with line 1” from bead (see Fig. 9.2).

Intercooler

Tube

• Position silicone reducer hose (2.25” - 2.5” dia.) and 2.25” hose clamp on over-engine-pipe (tube running forward across top of engine). Position hose clamp so it will not contact any surrounding components during engine movement (approx. .25” gap). Tighten clamp.

• Position second hose clamp (2.5”) on opposite end of silicone reducer hose.

Retaining

Silicone

Hose

Bead

1”

Mark

Line

• Install bellows (hump) silicone hose (2.5” dia.) and 2.5” hose clamp on Intercooler inlet (see Figs. 9.3a and 9.3b). Position properly behind bead and tighten hose clamp (see Fig. 9.2).

• Position a second hose clamp (2.5”) on opposite end of silicone bellows hose at Intercooler inlet.

• Install intercooler inlet tube. Both ends of tube will be inserted into the respective hoses at the same time.

Hose and Clamp Placement Diagram

Hose

Clamp

Figure 9.2

• Position tube so it will not contact any surrounding components, a .25” gap should be sufﬁcient to allow for engine movement.

• Position wiring harness forward towards radiator.

• When tube is properly positioned, tighten hose clamps.

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Volvo S60R Intercooler System / Installation Manual

• On vehicles with small AC dryer canister check for clearance issues with AC dryer line and carefully adjust line position as needed.

• Carefully check for clearance issues with wiring harness and adjust as needed. If the harness is allowed to make contact with the engine accessory drive belt or pulley it will be damaged quickly and this damage can be expensive.

Note: There is a small plastic tab located on the back of the radiator assembly, for positioning the wiring harness, which may rub on

Figure 9.3a

Figure 9.3b

tube. If it does rub, carefully remove the tab with a hacksaw and ﬁle rough edges.

9.3 Install Intercooler Outlet Tube

Note: Tube is equipped with a port to allow for installation of Aquamist water injection system. Remove port plug for use.

• Mark both ends of intercooler outlet tube with line 1” from bead, as shown in Figure 9.2.

• tion hose and clamp properly behind retaining bead and tighten hose clamp (see Fig. 9.2).

• Position a second hose clamp (2.5”) on opposite end of silicone hose. Note position of clamp (see Fig. 9.4c).

• Install intercooler outlet tube. Do not tighten clamps.

Figure 9.4a Figure 9.4cFigure 9.4b

9.4 Install Throttle Inlet Tube

• Mark both ends of throttle inlet tube with line 1” from bead (see Figure 9.2).

• On la hose extends past end of throttle inlet tube. You will need estimate position of hose clamp and test install onto throttle inlet to determine ﬁnal position. When ﬁnal position is determined, tighten hose clamp.

• Position second hose clamp (3.0”) on silicone hose and install on throttle inlet. Be sure hose and clamp are seated squarely against throttle inlet. Snug hose clamp to allow you to rotate hose into position with intercooler outlet tube.

• Install straight silicone hose (2.5” dia.) and hose clamp (2.5”) on other end of throttle inlet tube. Do not tighten.

• tioning hose and clamps according to bead reference line. Position tubes with a minimum of .25” of clearance to all surrounding components. Check that silicone hose and hose clamp at throttle inlet are still squarely seated against throttle inlet.

• Tighten hose clamps, including throttle inlet clamp.

• Recheck clearance of both tubes, providing a minimum of .25” of clearance from all surrounding components. Adjust as needed.

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Volvo S60R Intercooler System / Installation Manual

9.5 Install Hoses and IAT Sensor

• Reinstall vacuum/boost hose, attaching to hose boss on throttle inlet tube (see Fig. 9.5).

• Using supplied bolt and washer, reinstall IAT sensor attaching to mounting boss on intercooler outlet tube as shown (see Fig. 9.5).

• Reconnect IAT sensor wiring harness.

9.6 Recheck Clearances and Hose Clamps

Before proceeding, recheck all tube clearances. Also recheck all hoses and hose clamps to ensure they are properly positioned to the bead reference lines and are properly tightened. Be sure to check both hose clamps at the throttle inlet.

At this time also check for any wiring harnesses or other components that may have come loose during the installation. This is especially important in the area surrounding the engine drive belts as any loose wiring or component that comes into contact with this belt could be severely damaged.

15 minutes spent looking for potential problems now can prevent expensive and/or dangerous damage later.

10.0

Reinstall Air Filter Assembly

Vacuum/Boost

Hose

IAT Sensor

Figure 9.5

Reinstall air ﬁlter box in reverse sequence of removal (Section 3.0, pg. 4).

• Reattach vacuum line bundle to tab on side of air ﬁlter box.

• Insert air ﬁlter outlet into air inlet tube. This tube will snap in place when properly positioned.

• Reconnect mass air sensor harness.

• Install three bolts securing air ﬁlter box. Only tighten lower right bolt, leave others loose so air ﬁlter box can be shifted during installation of cold air snorkel.

• Insert cold air snorkel into slot in radiator bulkhead. Be sure the snorkel ﬁts over receiver within the radiator bulkhead.

• Install bolts securing cold air snorkel to radiator bulkhead. Tighten.

• Insert other end of cold air snorkel into air ﬁlter box. Be sure tabs engage.

• Install bolts securing cold air snorkel to air ﬁlter box and tighten.

• Tighten remaining two air ﬁlter box bolts.

• Tighten hose clamp connecting air ﬁlter box to air inlet tube.

11.0

NOTE: PRIOR TO STARTING ENGINE BE SURE RADIATOR HOSES ARE SECURELY REINSTALLED AND ENGINE COOL-

ANT HAS BEEN REPLACED AND IS AT RECOMMENDED LEVEL. FAILURE TO REPLACE COOLANT CAN RESULT IN SEVERE ENGINE DAMAGE.

Be check the engine and make sure all components are functioning properly. The car will not be driven at this time, but this will allow you to determine that all wiring harnesses, vacuum/boost lines, and intercooler tubes have been connected properly.

Start Engine and Check Connections

Page 18

Volvo S60R Intercooler System / Installation Manual

• Remove car from jack stands or lift.

• Reconnect battery.

• Start engine and allow engine to warm to operating temperature. Watch temperature gauge closely and check for function of engine cooling fan. Shut off engine immediately if any gauges or engines lights indicate abnormal function.

• Engine should idle and rev normally. If it does not, shut off engine and check for loose intercooler tubes/hoses and disconnected wiring harnesses. 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.

12.0

Trim and Install Front Fascia (Nose Section) Substructure

This step requires relatively easy trimming of the plastic and styrofoam components of the front fascia substructure. All components being trimmed or cut are replaceable, no permanent components are modiﬁed, to allow the vehicle to be returned to original condition if so desired. All trimming can be accomplished with a hacksaw or cutting wheel, however use of a band saw, if available, will greatly speed the process. After cutting clean all rough edges with a ﬁle and/or sand paper.

Note: To protect paint of the front fascia it is recommended the work area be clean and the fascia be placed on a soft cloth.

Please note, the trim lines shown in these photographs will result in a proper ﬁt, however you may wish to remove less material.

12.1 Remove Plastic Substructure and Styrofoam

• Carefully place the front fascia on suitable work surface and remove fog light support braces from front fascia. One per side.

• Separate plastic substructure from front fascia. Plastic substructure is attached by numerous plastic clips.

• Separate styrofoam impact strip from plastic substructure.

• Using grease pencil mark a line 5/8” from front of styrofoam impact strip (see Fig. 12.2). Front section of styrofoam will be discarded. Do not damage rear section during cutting as it will be reattached to the plastic substructure.

• Mark and trim plastic substructure as shown in Figures 12.3 - 12.10. This trimming is not exact, but should be close to what is shown in photographs to allow proper ﬁt of front fascia. All trimming can be accomplished with a hacksaw or cutting wheel, however use of a band saw, if available, will greatly speed the process. After cutting clean all rough edges with a ﬁle and sand paper.

After trimming, test ﬁt front fascia for proper ﬁt. Trim additional material as needed.

• When satisﬁed with ﬁt of front fascia, secure plastic substructure to bumper reinforcing bar using factory bolts that were used to secure front fascia to bumper reinforcing bar. (see Fig. 12.1).

• Using masking tape, temporarily secure styrofoam impact grid in position to plastic substructure.

Mounting Bolt

Plastic Substructure and Styrofoam Impact Strip

Styrofoam Impact Strip

Plastic Substructure

Mounting Bolt

Figure 12.1

Page 19

Volvo S60R Intercooler System / Installation Manual

Trim Line

5/8” from Front Edge

Discard Front Section

Trim Line on Styrofoam Impact Strip

Plastic Substructure Trim Line Detail

Figure 12.2

Figure 12.3

Plastic Substructure After Trimming

Figure 12.4

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Volvo S60R Intercooler System / Installation Manual

Plastic Substructure Trim Line Detail

Plastic Substructure After Trimming (also showing styrofoam impact strip after trimming)

Figure 12.5

Figure 12.6

Plastic Substructure After Trimming

Figure 12.7

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Volvo S60R Intercooler System / Installation Manual

Plastic Substructure After Trimming

Plastic Substructure and Styrofoam Impact Strip After Trimming

Figure 12.8

Figure 12.9

Plastic Substructure After Trimming

Figure 12.10

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Volvo S60R Intercooler System / Installation Manual

13.0

This step requires relatively easy trimming of the plastic and urethane components of the front fascia and underbody tray. All trim-

Trim and Install Front Fascia (Nose Section)

ming can be easily accomplished with a hacksaw or cutting wheel and cleaned up with a ﬁle and sand paper.

You may also use a heated carpet knife to trim some of the urethane components (lower grill opening and driving light area). This method provides a very clean cut through the urethane and requires no additional ﬁnishing to the part. Please note, given the

This fascia urethane.

13.1 Trim Lower Grill Opening

To provide adequate room for the new intercooler it is necessary to trim the back of the lower grill opening (see Fig. 13.3). Volvo has provided a convenient trimming line in the form of the edge of the painted surface in this area (see Fig. 13.2a). You will be applying a strip of masking tape along this paint line to protect the paint and provide a cutting guide. Overlap tape onto unpainted surface by approximately 1/8”. This will prevent you from cutting through the painted surface and will prevent paint from chipping during the cutting process.

• Identify paint line on lower grill area (see Fig. 13.4a).

• Apply masking tape to the painted side of this line, covering painted

Area to be

removed

surface (see Fig. 13.4b).

• Using hacksaw, cutting wheel or heated knife, carefully cut along line.

• Clean up cut edge with ﬁle and sandpaper. The ﬁnished cut can be seen in Figure 13.4c.

Figure 13.3

Paint Line

Figure 13.4a

13.2 Trim Left Driving Light Area

To provide space for the intercooler inlet tube it is necessary to trim a portion of the front fascia in the area behind the left side (passenger side for US/Canada market cars) as shown in Figures 13.5 and 13.6a.

• Using grease pencil draw cut lines on front fascia as shown in Figure

13.6b.

• Using hacksaw or cutting wheel, carefully cut along lines.

• Clean up cut edges with ﬁle and sandpaper.

• Finished cut can be seen in Figure 13.6c.

13.3 Trim Left Driving Light Grill Tab

• Remove driving light insert from left side front fascia (passenger side for US/Canada market cars).

Figure 13.4b

Figure 13.4c

Area to be

Trimmed

Figure 13.5

Page 23

Volvo S60R Intercooler System / Installation Manual

Cut Lines

Figure 13.6a

• 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).

Figure 13.6b

Tab to be Removed

Driving Light Insert (Left)

Figure 13.6c

Figure 13.7

Figure 13.8a

• Install front mounting bolts and tighten.

• Install six plastic rivets across radiator bulkhead.

• Install headlight wipers and connect washer tubes.

Cut Line

Figure 13.8b

Page 24

Volvo S60R Intercooler System / Installation Manual

14.0

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.

• When the engine has cooled, check the area around the engine drive belts to be sure no wiring harnesses have worked loose and come into contact with the engine drive belts.

• Recheck engine coolant level and ﬁll as needed.

Installation is now complete.

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

Test Drive and System Checks

BIC S60R User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual