Theses are the subjects. Make sure the rear intercooler piping is included.
Making these yourself is time consuming, but making them
using mandrel piping will increase performance.
Note the general area where the intercooler must fit. Test fit and plan
the project carefully.
Remove the dozen clips retaining the heat shield underneath the hood.
The heat shield should be discarded, as it won't fit with the intercooler.
BONUS: Weight reduction!
Unscrew the 4 bolts holding the hood shroud plate. The lip is too deep
and we want the air to circulate evenly over the intercooler. BONUS:
(see last picture or this DIY)
Disconnect the coolant hose from the coolant tank.
Remove the bolt holding the coolant tank in place.
Using a fancy baby blue hat, disconnect the air intake and the turbo
piping to make room to work. Note that safety glasses should be used
at all times.
;)
From the firewall, remove the bracket holding the sensor.
Remove the bracket holding the wiring harness
in place. Discard it especially if it's as rusted as this one!
Unbolt the motor mount at the engine end as well as at the firewall. Remove
the bolt holding the ground at the firewall.
Cut the tie wrap clips holding the wiring harness to the firewall.
Notice the intercooler outlet doesn't align with the intake manifold.
We need to trim the motor mount bracket as well as the firewall.
CAREFULLY grind away the plate covering the motor mount. We suggest
you use a metal plate to cover and protect the fuel lines as well as
the wiring harness.
Be extremely careful not to cut the fuel lines. A fire extinguisher
is a must.
If you accidentally cut the wiring harness (as was the case...), reconnect
the wires. A small hand grinder is recommended.
A portion of the firewall was modified for additional clearance. The
silicone coupler reducer connecting the intercooler to the throttle
body had to be slimmed down.
Assess
the situation. The piping is the longest part of the project.
A lot of custom fabrication is required to get the tight piping bends
to interlock.
You must build a custom bracket for the coolant tank. The tank must
be higher than your radiator. We used a standard 90-degree angle-bracket.
Admire your work and take that well deserved break.
Fits great and looks almost stock. The blow-off valve from the WRX was
painted gloss black for that aftermarket look.
The bonus? You can show off your intercooler thru the stock hood scoop!
If you're seeking a more "sleeper" look, put a black grill
on the inside of the hood.
