Engine Intake System (Induction) And Turbocharger (WRX): Intercooler: Installation

Install the insulator and clamp to the intake duct.
NOTE:
- Use a new insulator.
- Apply a thin coat of SUBARU PS fluid (K0515YA000) or liquid paraffin to the inner periphery of the insulator.
Fig 1: Locating Insulator And Intake Duct Clamp
Courtesy of SUBARU OF AMERICA, INC.
Install the intercooler stay RH to the engine hanger stay.
Tightening torque:

16 N.m (1.6 kgf-m, 11.8 ft-lb)

Fig 2: Locating Intercooler Stay RH Nut
Courtesy of SUBARU OF AMERICA, INC.
Set the urethane sheet (A) so that it covers the operating cylinder. (MT model)
NOTE:
- This procedure is required to prevent the intercooler from touching the operating cylinder during intercooler installation.
- Use the urethane sheet with the size (width x height x thickness) of approx. 300 mm x approx. 200 mm x approx. 10 mm (approx. 11.81 in x approx. 7.87 in x approx. 0.39 in).
Fig 3: Identifying Urethane Sheet (MT Model)
Courtesy of SUBARU OF AMERICA, INC.
Insert the intercooler into the intake duct No. 2, and temporarily tighten the clamp which secures the intake duct No. 2 to the intercooler.
NOTE: When inserting the intercooler into the intake duct No. 2, be careful that the insulator is not turned over.

Fig 4: Locating Intake Duct No. 2 Intercooler Clip
Courtesy of SUBARU OF AMERICA, INC.
Insert the intercooler into the intake duct No. 3, and tighten the clamp which secures the intake duct to the intercooler.
NOTE: When inserting the intercooler into the intake duct No. 3, be careful that the insulator is not turned over.

Tightening torque:

3 N.m (0.3 kgf-m, 2.2 ft-lb)

Fig 5: Locating Intake Duct No. 3 Intercooler Clip
Courtesy of SUBARU OF AMERICA, INC.
Pull out the urethane sheet (A) between intercooler and operating cylinder. (MT model)

Fig 6: Identifying Urethane Sheet Between Intercooler And Operating Cylinder
Courtesy of SUBARU OF AMERICA, INC.
Set the intercooler stay LH to the intake manifold, and temporarily tighten the bolts which secure intercooler stay LH to the intake manifold.
Install the bolt which secures the intercooler to the intercooler stay.
Tighten the bolts which secure the intercooler stay LH to the intake manifold, and install the brake booster vacuum hose to the clip (A).
Tightening torque:

16 N.m (1.6 kgf-m, 11.8 ft-lb)

Fig 7: Identifying Brake Booster Vacuum Hose Clip
Courtesy of SUBARU OF AMERICA, INC.
Connect the ground terminal to battery sensor. < Ref. to BATTERY , NOTE, Note. >
Install the collector cover. < Ref. to INSTALLATION , Collector Cover. >