Section 2 (Engine Intake System (Induction) And Turbocharger (WRX-STI)): Intercooler: Installation

WARNING: This page is about a different variant/trim than selected.

Install the intercooler stay RH No. 1, and install the clip (A) which secures the engine harness to the intercooler stay RH No. 1.
Tightening torque:

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

Fig 1: Locating Intercooler Stay Clip RH No. 1
Courtesy of SUBARU OF AMERICA, INC.
Attach the air duct hose to the throttle body.
Tightening torque:

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

Fig 2: Locating Throttle Body Air Duct Hose
Courtesy of SUBARU OF AMERICA, INC.
Set the intercooler to the vehicle, and install the bolts securing the intercooler to the intercooler stay RH No. 1.
Tightening torque:

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

Fig 3: Locating Intercooler Stay Bolt RH No. 1
Courtesy of SUBARU OF AMERICA, INC.
Temporarily tighten the bolt securing the intercooler stay LH to the intake manifold.

Fig 4: Locating Intercooler Stay LH Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the bolts which secure the intercooler to the intercooler stay LH, 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 5: Locating Brake Booster Vacuum Hose Intercooler Bolt
Courtesy of SUBARU OF AMERICA, INC.
Tighten the bolt securing the intercooler stay LH to the intake manifold.
Tightening torque:

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

Fig 6: Locating Intercooler Stay LH Bolts
Courtesy of SUBARU OF AMERICA, INC.
Tighten the clamp (A) which secures the intake duct to the turbocharger.
Tighten the clamp (B) which secures the air duct hose to the intercooler.
Install the bolts (C) which secures the air by-pass valve to the intercooler, and install the air by-pass valve.
NOTE: Use a new gasket.

Tightening torque:

T1: 3 N.m (0.3 kgf-m, 2.2 ft-lb)

T2: 16 N.m (1.6 kgf-m, 11.8 ft-lb)

Fig 7: Identifying Intercooler Air By-Pass Valve Bolts With Torque Specifications
Courtesy of SUBARU OF AMERICA, INC.
Install the PCV pipe to the intercooler.
Tightening torque:

5.5 N.m (0.6 kgf-m, 4.1 ft-lb)

Fig 8: Locating PCV Pipe Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the chamber assembly. < Ref. to INSTALLATION , Chamber Assembly. >