Installation Manual Volvo V70R Front Mount Intercooler System
Volvo V70R Intercooler System / Installation Manual C 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 Air Filter Assembly 4 4.0 Removing Factory Intercoolers and Tubes 5 5.0 Drilling, Trimming and Misc. 7 6.0 Installing New Intercooler 9 7.0 Installing New Intercooler Tubes 10 8.0 Reinstall Air Filter Assembly 13 9.0 Start Engine and Check Connections 13 10.
Volvo V70R Intercooler System / Installation Manual 1 Parts List Part Name Packet Qty Part Number Intercooler Assembly Intercooler 1 A3001361806070(B) Intercooler Inlet Tube Components 1 PLV6070-01-B Intercooler Outlet Tube Components 1 PLV6070-02-B Throttle Inlet Tube Components 1 PLV6070-03-B Straight (2.5” ID x 3” L) Hose 1 P00503-0300BLAC Bellows/Hump (2.5” ID x 3” L) Hose 2 P00553-0300BLAC Straight (3.0” ID x 2.
Volvo V70R Intercooler System / Installation Manual 2 Required Tools and Materials To effici supplied with your intercooler.
Volvo V70R Intercooler System / Installation Manual 2.0 3 Removing Front Fascia (Nose Section) Note: Before beginning any work on the vehicle the battery must be disconnected and the AC system must be evacuated. 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).
Volvo V70R Intercooler System / Installation Manual 4 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.
Volvo V70R Intercooler System / Installation Manual 4.0 5 Removing Factory Intercoolers and Tubes Inlet Tube 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.
Volvo V70R Intercooler System / Installation Manual 6 4.5 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. 4.6 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.
Volvo V70R Intercooler System / Installation Manual 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 4.7. 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 4.8a and 4.8b. • Grip the AC dryer canister firmly with both hands or with a large pair of channel lock pliers.
Volvo V70R Intercooler System / Installation Manual 8 Mounting Bolt • Remove horns and original brackets. Locate and remove 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.” Bracket (Left) Horn (Left) Front • Remove factory brackets from each horn. Secured with a single bolt which will be used to attach the new horn brackets.
Volvo V70R Intercooler System / Installation Manual 9 • Using a grease pencil draw a line straight back from the edge of the existing hole in the radiator bulkhead (Items A in Figure 5.4b). • Draw a line across, connecting the two previous lines, 3 inches from the bottom of the opening (Item B in Figure 5.4b). • Radius each of the upper corners as shown in Figure 5.4b. A .5” radius is shown. Using a hacksaw or cutting tool, cut carefully along lines. Exercise care to avoid damaging the radiator.
Volvo V70R Intercooler System / Installation Manual 10 Spacer • Move intercooler into position in front of AC condenser. Be careful not to damage cooling fins on Intercooler or AC condenser. Narrow • Install mounting fasteners and spacers through as shown in Figure 6.3. Be sure spacers are rotated as shown, with widest section to the bottom, to ensure proper spacing between the intercooler and AC condenser.
Volvo V70R Intercooler System / Installation Manual 11 • 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.
Volvo V70R Intercooler System / Installation Manual Figure 7.4a 12 Figure 7.4b Figure 7.4c • 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.
Volvo V70R Intercooler System / Installation Manual 8.0 13 Reinstall Air Filter Assembly 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.
Volvo V70R Intercooler System / Installation Manual 10.0 ! 14 Trim and Install Front Fascia (Nose Section) This step requires relatively easy trimming of the plastic and urethane components of the front fascia and underbody tray. All trimming can be easily accomplished with a hacksaw or cutting wheel and cleaned up with a file and sand paper. 10.1 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. 10.1).
Volvo V70R Intercooler System / Installation Manual 15 Cut Lines Figure 10.4a Figure 10.4b Figure 10.4c 10.4 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 10.6a. • Using grease pencil, draw cut lines on underbody tray (see Fig. 10.6b). • Using hacksaw or cutting wheel, carefully cut along lines.
Volvo V70R Intercooler System / Installation Manual 11.0 16 Test Drive and System Checks Test Drive and System Checks 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.
