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Home >> Subaru >> 2017 >> Forester 2.0XT Touring >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Intake System (Induction) And Turbocharger (H4DOTC) >> Intercooler >> Installation

Engine Intake System (Induction) And Turbocharger (H4DOTC): Intercooler: Installation

  1. 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 Clamp To Intake Duct
    G09480104Courtesy of SUBARU OF AMERICA, INC.
  2. 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 Engine Hanger Stay Nut
    G09480106Courtesy of SUBARU OF AMERICA, INC.
  3. Temporarily tighten the intercooler stay LH to the intake manifold.
  4. Install the brake booster vacuum hose to the clip (A).
    Fig 3: Locating Intercooler Stay LH With Bolts
    G09480107Courtesy of SUBARU OF AMERICA, INC.
  5. 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 To Intercooler With Clamp
    G09480108Courtesy of SUBARU OF AMERICA, INC.
  6. 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 To Intercooler With Clamp
    G09480109Courtesy of SUBARU OF AMERICA, INC.
  7. Install the bolts which secure the intercooler to the intercooler stay, and tighten the bolt which secures 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 Bolts
    G09480110Courtesy of SUBARU OF AMERICA, INC.
  8. Move the lock lever in the direction of the arrow, and connect the connector to the ECM in numerical order as shown in the figure.
    Fig 7: Moving Lock Lever
    G09480111Courtesy of SUBARU OF AMERICA, INC.
  9. Connect the battery ground terminal. Ref. to NOTE>NOTE>BATTERY .
  10. Install the collector cover.
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