Engine Intake System (Induction) And Turbocharger (2.0L): 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 Of Intake Duct
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 Bolts
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: Setting Urethane Sheet To Cover Operating Cylinder
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 Clamp Of Intake Duct No. 2 And Intercooler
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 Intercooler And Intake Duct No. 2 Clamp
Courtesy of SUBARU OF AMERICA, INC.
Pull out the urethane sheet (A) between intercooler and operating cylinder. (MT model)

Fig 6: Pulling Out 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: Locating Intercooler Stay LH And Intake Manifold Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the collector cover. <Ref. to INSTALLATION , Collector Cover.>