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Anleitung Zusammenfassung
C30-IMv1 i C Contents Important Information i Parts List i Required Tools and Materials 1 1.0 - Vehicle Preparation 1 2.0 - Removing and Trimming Front Fascia (Nose Section) 2 3.0 - Removing Factory Intercoolers and Tubes 3 4.0 - Installing New Intercooler 4 5.0 - Start Engine and Check Connections 6 6.0 - Trim and Install Front Fascia (Nose Section) 7 7.0 - Test Drive 8 Important Information Congratulations on your purchase of the Bell Intercoolers Volvo C30 T5 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 materials that may be required for successful installation. 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. 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. ! Parts List Part Name Packet/Box Qty Intercooler Assembly -- 1 M8 - 1.25 x 60mm Bolt - Hex Head Parts - Bag 1 2 M8 Flat Washer Parts - Bag 1 2 M5 - 0.8 x 20mm Bolt - Hex Head Parts - Bag 1 1 M5 Flat Washer Parts - Bag 1 1 Hose Clamp - T-Bolt 2.5” Parts - Bag 2 2 1 Required Tools and Materials To effici supplied with your intercooler. Tools • 1/4” Drive Ratchet • T20 and T30 Torx Bits and Suitable Driver • 1/4” Drive Extensions - 3” Length • Small Flat-head Screwdriver • 3/8” Drive Ratchet • Phillips Screwdriver • 3/8” Drive Extension - 3” Length • Hacksaw or Cutting Wheel • Sockets 8 - 17 mm (1/4” or 3/8” Drive) • Round and Flat File (optional) • 11 mm Deep Socket • Vehicle Jack or Lift • Wrenches (Open/Boxed) 8 - 17 mm • Jack Stands (x2) • Straight Edge Ruler Materials • WD-40, Motor Oil or Lubricant • Grease Pencil or China Marker (non-permanent) Vehicle Preparations 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 inlet tube can cause serious and expensive damage when the engine is started, possibly damaging valves, cylinders and pistons. An easily avoidable, but expensive proposition. While performing the installation keep the any open intake tubes (air intake, etc.) covered with a clean rag and thoroughly check all tubes, hoses and the intercooler for any foreign objects or debris before installing. 1.1 Disconnect Battery As a matter of safety you should disconnect the negative battery terminal before beginning any work on this installation. This is done to prevent any unintentional shorting of electrical components and to remove the danger of accidentally energizing the starter motor with a tool. The battery is located in the right rear corner of the engine and is covered. • Locate battery and remove cover (Fig. 1.1). To remove cover pull out on sides and lift front. • Disconnect the negative terminal (Fig. 1.2) and move battery cable away from negative post. 1.2 Jack Stands or Lift Installation of this intercooler system can be accomplished without placing the vehicle on a lift or jack stands. However, you will find the installation process much easier with the car elevated. If you will be lifting the car please consult Volvo service manual proper jack, jack stand and/or lift placement. Be sure vehicle is securely positioned before proceeding. 1.0 Battery Cover Figure 1.1 Negative Terminal Figure 1.2 Removing Front Fascia (Nose Section) The first step in the installation will involve removal of the front fascia (front nose section) of the vehicle (see Fig. 2.1). The front fascia of the C30 is comprised of two pieces, an upper section and a lower section, as shown in Figure 2.1. These two sections remaining joined during the installation process and will not be separated. 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 (if so equipped). 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. In addition to the front fascia there is a plastic splash guard positioned underneath the engine. This piece must be removed for installation. To reduce the chance of damaging the vehicle paint on th...