Volvo C30 T5 Intercooler System / Installation Manual
7
Bell Intercoolers, inc. © 2008 All rights reserved. C30-IMv1
Trim and Install Front Fascia (Nose Section)
This step requires relatively easy trimming of the plastic and urethane components of the front fascia. All trimming can be easily
accomplished with a hacksaw or cutting wheel and cleaned up with a file and sand paper.
6.1 Remove Lower Grill Insert
The plastic grill insert in the lower grill opening is secured by nine plastic tabs. Carefully release tabs and remove grill insert.
6.2 Mark and Trim Lower Grill Opening
- Standard Trim Pattern
To provide adequate room for the new
intercooler it is necessary to trim the back
of the lower grill opening. For more ag-
gressive cooling of the intercooler you may
wish to use the optional trimming pattern
shown in Step 6.3 (see Fig. 6.2).
• At each corner of bottom surface mark a
line 1/2” from back edge (see Fig. 6.1).
• At each corner of top surface mark a
line 1/2” from back edge (see Fig. 6.1).
• Using a straight edge, mark line across
bottom surface connecting corner marks
(see Fig. 6.1).
• Repeat for top surface (see Fig. 6.1).
• Draw lines on side surfaces connecting
upper and lower corners (see Fig. 6.1).
• Using hacksaw or cutting wheel, care-
fully cut along lines.
• Carefully clean up cut edges with file
and/or sandpaper.
6.3 Mark and Trim Lower Grill Opening
- High Temperature Trim Pattern
If you are planning on running your car at
track events or if you live in a hot climate
you may wish to use a more aggressive
trimming option for the grill opening. This
option removes more material from the
upper surface of the grill opening which al-
lows more air to reach the upper portion of
the intercooler core. This trimming pattern
is shown in Figure 6.2.
• At each corner of bottom surface mark a
line 1/2” from back edge (see Fig. 6.1).
• Using a straight edge, mark line across bottom surface connecting corner marks (see Fig. 6.1).
• At each corner of top surface, points A and D in Figure 6.2, mark a line 1/2” from back edge.
• As shown by points B and C in Figure 6.2 make a mark 1 1/2” from back edge of upper surface and 1 1/2” from the outer edge
of the upper surface. Repeat for both sides of upper surface.
• Using a straight edge, mark line connecting points A and B, B and C, C and D, as shown in Figure 6.2..
6.0
Figure 6.1
Standard Trim Pattern
Upper Corner
Mark 1/2” From
Back Edge
(Lower Corner)
Mark 1/2”
From Back Edge
Upper
Cut Line
Bottom
Cut Line
(Lower Corner)
Mark 1/2”
From Back Edge
(Upper Corner)
Mark 1/2”
From Back Edge
Figure 6.2
Optional High Temperature Trim Pattern
Upper
Cut Line
Bottom
Cut Line
B
C
A
D
(Lower Corner)
Mark 1/2”
From Back Edge
(Lower Corner)
Mark 1/2”
From Back Edge
