Volvo C30 T5 Intercooler System / Installation Manual
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Bell Intercoolers, inc. © 2008 All rights reserved. C30-IMv1
• Loosen hose clamp securing intercooler outlet hose to intercooler
and disconnect hose from intercooler.
3.3 Remove Hose Clamps
The factory hose clamps will be replaced with high-strength T-bolt
hose clamps for use with your new intercooler. You will need to re
-
move the factory hose clamps prior to installing the new intercooler.
• Carefully remove factory hose clamps from intercooler inlet and
outlet hoses. These clamps are secured by a small metal barb
that grips the rubber hose. To release the barb carefully pry barb
away from hose. Once the barb is clear of the hose you may safely
remove the hose clamp.
3.4 Disconnect Intake Air Temperature (IAT) Sensor Harness
• Locate wiring harness connected to Intake Air Temperature (IAT)
sensor (see Fig. 3.2).
• Disconnect wiring harness from IAT sensor.
3.5 Remove Intercooler
• Locate and remove the two (2) T30 Torx fasteners securing the
intercooler to the radiator assembly, one fastener per left and right
side (see Fig. 3.3).
• Intercooler is positioned with two plastic tabs at the lower corners.
Lift intercooler to disengage these tabs and remove intercooler.
3.6 Remove IAT Sensor
• Locate the IAT sensor on intercooler (see Fig. 3.4).
• Remove the one (1) T20 Torx fastener securing IAT sensor to inter
-
cooler.
• Carefully remove IAT sensor from intercooler. Sensor uses an o-
ring, use care when removing the sensor so as to prevent damage.
3.7 Remove Crossmember Mounting Bolts
Your new intercooler will be mounted using the front two (2) bolts
securing the radiator lower crossmember (See Figs. 3.5 and 3.6).
• Locate and remove indicated fasteners (see Figs. 3.5 and 3.6).
Installing New Intercooler
New Components
Intercooler Assembly (x1)
M5 - 0.8 x 20mm Bolt - Hex Head (x1)
M8 - 1.25 x 60mm Bolt - Hex Head (x2)
M5 Flat Washer (x1)
M8 Flat Washer (x2)
Hose Clamp - T-Bolt 2.5” (x2)
4.1 Install IAT Sensor
Prior to installing the new intercooler you will need to install the fac-
tory IAT sensor. This sensor installs in the same general position as
Figure 3.3
Figure 3.4
Figure 3.5
Figure 3.6
4.0
IAT
Sensor
Mounting
Bolt
Left Front
Crossmember
Mounting
Bolt
Right Front
Crossmember
Mounting
Bolt
