BSR Optiflow User manual

Assembly instruction
Volvo S40/V50 T5 2004>
Page 1
\\Server\bsr ler\Teknik\Monteringsanvisningar\OptiFlow\Volvo\Engelska\S40V50\Assembly instruction.pdf
Read this before assembly!
Carfully check for dirt and particles in all pipes
and hoses. Also check for dirt inside the lter.
At smallest hesitation, clean and wipe everyth-
ing thoroughly before assembly!
Check hoses for deformations, cracks or other
leakage. The clamps should be in good condi-
tion or to be replaced. Please note, when tting
BSR air lter, do not tighten the air lter to hard,
be gentle. Check before and after testdrive that
everything are tight and rm.

Assembly instruction
Volvo S40/V50 T5 2004>
Proposal of tools:
•¼ Catch, Extender, socket 7, 8,10 mm
•½ Catch, Extender, socket 15 mm
Page 2
•Phillips screw driver
•Wrench 8 mm
•Torx 25, 30
•Wire cutter
•Car jack
1. Material overview.
2.Remove the plastic cover (1) above the ECU
by pulling. Remove the inlet tubing (2). Remove
screws and turn pipe 45º clockwise.
Remove the inlet pipe (3) from the inlet by pushing
the red ring and at the same time pulling the pipe.
Remove the hose (4) from the air mass meter.
3.Disconnect the battery.
Release the connector from the air mass meter.
4. Remove the connectors from the ECU.
Loosen both of the red clips and pull the con-
nectors. 5. Remove the cable harness from the air lter
box. Cut of the tie wrap holding the harness.
Remove screw (5).
6. Remove the cable harness from the air lter box.
8. Pull the airlter box straight up until lets go of the
rubber bushing.
Then pull the box to the left and turn it at the same
time upwards to release it.
Remove the ECU and the air mass meter from the
air lter box.
7. Remove the two bolts from the right hand side
engine mounting.
Remove the protective cover from under the engine.
Put the car jack under the oil pan and lift up the
engine slightly, max 10-15mm. Push the engine
backwards.
9.Cars with automatic gear box:
Open the electrical harness cover.

Page 3
Assembly instruction
Volvo S40/V50 T5 2004>
Proposal of tools:
•¼ Catch, Extender, socket 7, 8,10 mm
•½ Catch, Extender, socket 15 mm
•Phillips screw driver
•Wrench 8 mm
•Torx 25, 30
•Wire cutter
•Car jack
10. Assemble the 6 plastic clips to the plate (8).
Assemble the air mass meter and the ECU to the
OptiFlow heat shield . Assemble the rod (9). (as
picture shows)
11. Assemble the plastic ”washer” to the rubber-
bushings (7).
12. Assemble the OptiFlow heat shield to the car,
slide it down from right to left. Fit the steering pin
under the Optiow heat shield to the rubber bushing
(See pic 11 point 6).
13. Tighten the heat shield, start with the two attach
points to the left, leave the third for later
14. Assemble the harness connector and the air
hose to the air mass meter. Assemble the two har-
ness connectors to the ECU. Snap on the red locks.
Assemble the vaccum pipe to the inlet.
15. Assemble BSR air hose (10) and performance
air lter(11). Assemble the rod(13) as picture.
Lower the engine and assemble the bolts to the
engine mounting.
Assemble the inlet tubing (12) and reconnect the
battery.