Our race winning attention to detail doesn’t end with the hardware. To ensure a smooth installation process we created a comprehensive 8-page installation manual covering every aspect of the installation process. From start to finish, we provide detailed instructions, photos and illustrations for each step of the installation. We also provide a full list of the tool and materials required. Whether you will be handling the installation yourself or having a shop or dealership do the job, you can be assured that the intercooler system will be installed properly and will perform as designed.

Difficulty Level
It’s a 3. Ranked on a scale of 1 to 10, with 1 being changing a tire and 10 being an engine rebuild, the installation of this system is a 3.

Unsure if you want to handle the installation yourself? Download the manual and read through the process. To help you make that decision we have marked any steps that may be mechanically advanced or require special tools. The Volvo S40 T5 Front Mount Intercooler System is designed to be a true bolt-in system that can be installed by the home mechanic using standard tools. No welding, machining or fabricating is required and all components are designed to assemble easily and provide a professional, factory quality appearance. Minimal trimming of factory components is required (see manual for details).

Time Required
Estimated installation times will vary depending on the mechanical skills of the installer. For an experienced mechanic or tuning shop the installation should require 2-3 hrs. For the average home mechanic with proper tools the installation should require 4-6 hrs. The difference in times is not an indicator of mechanical complexity, just an indicator that the average home mechanic may not have the familiarity with the process and will review each step carefully before proceeding, taking more time to be sure each step is completed properly.