User Manual

Volvo S40 T5 Intercooler System / Installation Manual
3
Bell Intercoolers, inc. © 2009 All rights reserved. S40-IMv1
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 driv-
ing 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).
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 inter-
cooler 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.
Figure 2.4
Figure 2.5
Driving Light
Assembly
Harness
Connector
Location
Upper Radiator
Bulkhead
3.0
Figure 3.1
Intercooler
Air Guide
Mounting
Tabs
Figure 3.2
Intercooler
Inlet Hose
IAT Sensor
Harness