PI-379 04/10 Dedicated to improving vehicle fun, safety & performance Installation Instructions PI379 Air Intake System for S60R and V70R (2004-07) ipd #2C8500 SUGGESTED TOOLS 8mm socket with ratchet Flat blade screwdriver 10mm socket with ratchet T25 Torx bit/driver Pliers INTRODUCTION Please completely read through these instructions to familiarize yourself with the project. There are no cutting, drilling or other modifications required to install the air management system (AMS). Retain all hardware as much of it will be reused in fitting the air management system. INSTALLATION 1 Familiarize yourself with the uner hood components and their location. 11744 NE Ainsworth Circle, Portland, OR 97220 (503) 257-7500 Fax (503) 257-7596
2 Remove cover by depressing the three tabs and pulling cover up and off. depress tabs and remove cover 3 Remove two bolts (8mm head) holding Intake Snorkel to Stock Air Box. Once bolts are removed, pull the Intake Snorkel out of the Stock Air Box. There are tabs molded into the Intake Snorkel that clip into the Stock Air Box that will release as you pull the Intake Snorkel off. STOCK AIR BOX INTAKE SNORKEL 4 Using a flat blade screwdriver, loosen MAF (Mass Air Flow) Sensor clamp so that it is very loose. Unclip MAF Sensor terminal. 2 Air Intake Management System for S60R and V70R 2009 ipd, PI-379
Remove three bolts (8mm head) holding Stock Air Box to brackets. Unclip TCV (Turbo Control Valve) 5 from side of Stock Air Box and release vacuum lines to/from TCV from hanging bracket below MAF Sensor. Remove entire Stock Air Box by pulling it out of the hose connecting the MAF Sensor to the plastic pipe to the turbo. FREE VACUUM LINES FROM BRACKET REMOVE THREE BOLTS (8mm HEAD) TCV UNCLIP TCV FROM AIR BOX 6 With the Stock Air Box now removed, remove the bracket that the Cover clipped on to by removing three bolts (10mm head). REMOVE THREE BOLTS (10mm HEAD) VACUUM SOLENOID Vacuum Solenoid 2009 ipd, PI-379 Air Intake Management System for S60R and V70 3
7 Depress tab and remove bracket from vacuum solenoid. Depress tab and release hose from bracket. 8 Loosen clamp on hose from Vacuum Solenoid to intake manifold. Remove hose by pulling out of vacuum solenoid and plastic fitting to intake manifold at the other end. loosen clamp, remove hose plastic fitting to intake manifold vacuum solenoid 9 Replace hose between Vacuum Solenoid and Intake Manifold with new, shorter, 7 (18mm) hose included with Air Management System. Reuse the hose clamp at plastic fitting to Intake Manifold. Use included zip tie to secure hose into Vacuum Solenoid to bracket, below top plane of the bracket. secure hose to bracket, keeping vacuum solenoid low on bracket. new, shorter hose section clamped into place to plastic fitting as original. 4 Air Intake Management System for S60R and V70R 2009 ipd, PI-379
10 Unclip wiring harness connector from radiator support and allow wires and terminals to fall behind headlamp. 11 Remove MAF Sensor from Stock Air Box by removing the two T25 screws. Slide MAF Sensor out of the Stock Air Box. Retain vacuum line bracket. remove two screws (t25) and remove maf sansor from stock a box. 12 Position MAF Sensor onto AMS Box, oriented the same way as removed from Stock Air Box, with sensor terminal facing up. Make sure MAF Sensor slides over threaded studs and into AMS opening. Slide vacuum line bracket over lower stud. Draw MAF Sensor onto AMS Box by tightening the two nuts (10mm head). Snug nuts to MAF Sensor do not tighten to more than 8ftlbs (10Nm). secure maf sensor to ams box, including vacuum line bracket ith nuts (10mm head). 2009 ipd, PI-379 Air Intake Management System for S60R and V70 5
13 Ensure everything is ready for AMS Box fitting. 14 Prepare AMS Box for fitting into engine bay. Route and secure vacuum lines to/from the TCV into bracket under MAF Sensor as original. Secure TCV to tab on back of AMS Box. secure tcv to tab on back of ams box. route and secure vacuum lines in bracket. 15 With TCV and vacuum line secured under the MAF Sensor, position AMS Box to slide MAF Sensor into plastic pipe leading to turbo, as originally positioned. Do not tighten clamp yet. 6 Air Intake Management System for S60R and V70R 2009 ipd, PI-379
16 With the MAF Sensor attached to tube leading to turbo and the AMS box settled in place, line up the two mounting holes in AMS with bracket holes underneath. There is one mounting point (a) below the Air Filter mounting pipe and one (b) at the top left corner of the AMS Box. If the mounting holes in the AMS do not line up, the brackets underneath may be adjusted left or right by simply pushing or pulling on them as needed. Once lined up, use factory bolts (8mm head) to secure AMS to the two brackets. Use the large washer (included) under the bolt of mounting point (a) if needed. mounting point (B) mounting point (a) under air filter mount insert intake snorkel and attach to ams flange using original bolts. 17 Once the two mounting bolts are tightened, reconnect MAF Sensor terminal and tighten band clamp on MAF Sensor. 18 Mount desired Air Filter and secure using band clamp on the filter. Some Air Filters may require a ring adapter between inside of Air Filter mounting and outside of AMS mounting pipe. 2009 ipd, PI-379 Air Intake Management System for S60R and V70 7
HEADLAMP REMOVAL FOR TRACK EVENTS 1 For Track events, the left side headlamp assembly can be removed to allow additional air to be directed to the air filter. Removal of headlamp requires removal of front bumper to gain access to two of the four headlamp mounting bolts. Unplug all wiring terminals from back side of headlamp assembly, remove four mounting bolts, and remove headlamp from front of car. TOTAL OF FOUR MOUNTING BOLTS (8MM HEAD) 2 With headlamp assembly removed, partially remove rubber weather-stripping from AMS Box and slide up plastic window cover and remove. Reinstall weather-strip. 3 Position wiring so that it is secure and reinstall front bumper. Note that warning display on driver s information screen will register as a headlamp being nonfunctioning. WITH HEADLAMP REMOVED, TWO ADDITIONAL OPENINGS FEED AIR DIRECTLY TO THE AIR FILTER. 2009 ipd, PI-379 Air Intake Management System for S60R and V70 9
warranty One Year Limited Warranty ipd warrants to the original purchaser that the parts manufactured and/or sold by ipd (the Product) is free from defects in material and workmanship under normal use. ipd warrants that the Product will perform substantially in accordance with the specifications set forth in the documentation provided with it. The above express warranties are made for a period of the lesser of 12,000 miles or 12 months from the date the Product is installed in your vehicle. Any improper use, operation beyond capacity, substitution of parts not approved by ipd in writing, any alteration or repair by others, or any removal, defacing or altering of the identification shall void this warranty. There is no warranty on high-performance or race related parts due to the nature of usage. The purchaser shall notify ipd at 1-800-444-6473 of any defect within the warranty period no later than thirty (30) days after purchaser discovers the defect. Should any failure to conform to this warranty appear within the warranty period, ipd shall, on notification, correct the nonconformity at its option, either by repairing any defective part, or by making available, FOB ipd s plant, a repaired or replacement part. The purchaser must insure any defective item being returned because ipd does not assume risk of loss or damage while in transit. No payment or reimbursement shall be made for installation, removal, transportation or other charges. The remedies set forth in this instrument are exclusive, and the liability of ipd with respect to any sale shall not exceed the price of the product on which the liability is based. EXCEPT AS STATED OTHERWISE IN THIS WARRANTY, ipd MAKES NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. ipd shall not in any case be liable for special, incidental, consequential, indirect, or other similar damages arising from any breach of these warranties even if ipd or its agent has been advised of the possibility of such damages. Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you. This warranty is governed by the laws of the State of Oregon. 10 Air Intake Management System for S60R and V70R 2009 ipd, PI-379