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View Full Version : Intercooler removal and installation



fishawrx
11-21-2009, 06:54 PM
02 WRX

tools
10mm wrench
12mm wrench or socket/rachet
standard screwdriver, fairly beefy 4" or longer

Intercooler removal
1) Loosen hose clamps on turbo outlet and the coupler b/w the intercooler and throttle body.
2) Remove the 2 bolts on either side of the BOV
3) Remove the 3 small bolt/screws along the front of the intercooler * or leave these 3 screws in, remove the two hoses on either side of the intercooler. I prefer removing the screws, if you want to get these pipes out of the way (like for removing the intake manifold), then pulling the hoses is best.
http://i298.photobucket.com/albums/mm265/fishafisha/IMG_0941.jpg
4) Remove the mounting bolts on either side of the intercooler.
5) Push intercooler away from intake manifold and then towards the driver side. This should pull it loose from both the throttle body and the turbo outlet.
6) While the intercooler is off, this is a good time to check all of the y-pipe connections. If you have oil on the y-pipe around the hose clamps, this is probably the source of a boost leak.

Installation
1) Pull intercooler forward onto the throttle body.
2) Then align the y-pipe to the turbo outlet. There is a tab on the y-pipe in which you can place a screwdriver and pry the y-pipe onto the turbo outlet.
http://i298.photobucket.com/albums/mm265/fishafisha/IMG_0942.jpg
3) Replace all bolts from the removal
4) Make sure the coupler b/w the intercooler and throttle body, and the y-pipe to turbo connections, and the BOV bolts are all tight to avoid boost leaks.

WRXNFX
11-21-2009, 07:33 PM
optionally you can pull those hoses of the pipe on the front of the intercooler.

compro
11-21-2009, 07:34 PM
optionally you can pull those hoses of the pipe on the front of the intercooler.

thats what i have been doin

fishawrx
11-21-2009, 10:01 PM
true. that's just the way that i've always done it. This is part one of the write up for removing the intake manifold... more to come.

NoAffiliationSTi
11-24-2009, 09:58 AM
i prefer an open engine bay with a front mount :-)

bigboy
11-28-2009, 08:55 PM
i prefer an open engine bay with a front mount :-)


+1

fishawrx
11-28-2009, 09:48 PM
as do I, I'm just missing the front mount :x

compro
11-28-2009, 09:50 PM
im going light weight, no inter-cooler at all!

fishawrx
11-28-2009, 09:51 PM
wtf?!?!?