Installation manual

Volvo V70R Intercooler System / Installation Manual
10
Bell Intercoolers, inc. © 2009 All rights reserved. S601-V70R-IMv7
• 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 6.3. Be sure spacers are rotated as shown, with widest
section to the bottom, to ensure proper spacing between the inter-
cooler 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.
Installing New Intercooler Tubes
New Components
Intercooler Inlet Tube (x1) Hose Clamp (T-Bolt) - 3.0” (x2)
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)
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.
7.4b and 7.4c to allow for easy access for tightening while not rubbing on the front fascia bodywork.
7.1 Relocate Wiring Harness
To avoid damage to wiring harness due to close proximity to acces-
sory drive belt and pulley it is necessary to relocate a short portion of
the wiring harness. This section of wiring harness is located behind
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
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.
7.0
Figure 7.1
Intercooler
Inlet Tube
Intercooler
Outlet Tube
Throttle
Inlet Tube
Figure 6.3
Intercooler
Bracket
Bumper
Cross Member
Spacer
Wide
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Bracket and Fastener Diagram