Owner's manual
Volvo S60R Intercooler System / Installation Manual
6
Bell Intercoolers, inc. © 2009 All rights reserved. S601-S60R-IMv3
• 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.
Removing Factory Intercoolers
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 second-
ary intercooler to the AC condenser (see Items A in Fig. 5.1).
• Remove secondary intercooler and intercooler connection hoses.
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.
Figure 5.1
Illustration / Volvo Cars North America
Factory Intercoolers, Tubes and Hoses
Secondary
Intercooler
Primary
Intercooler
A
A
Inlet
Hose
Outlet
Tube
IAT
Sensor
Vacuum/
Boost
Port
5.0
Figure 4.2
Mass Air
Sensor
Hose
Clamp
Air Inlet
Tube