Front Mount Intercooler Kit fitting guide [02

Front Mount Intercooler
Installation Guide
PN# S2X01G9GA001A [silver]
PN# S2X01G9GA00BA [blue]
PN# S2X01G9GA00RA [red]
Applied Models:
2002-04 Impreza WRX
2002-04 Impreza STI
You are now the proud owner of a highly tested and proven AVOTurboworld upgrade kit. While
you have made a wise choice in selecting this upgrade kit, below we have some suggestions
and procedures for you to follow in ensuring its successful installation.
A) Orientation
Before grabbing a bunch of wrenches and attacking your car take a moment to
STOP AND THINK
Read these supplied installation instructions thoroughly from start to finish – do you understand all of the
mechanical operations required? Are you sure that you can adequately complete all of the mechanical operations
required?
Prior to installation, make sure that your car is in excellent mechanical condition and that there are no outstanding
faults or problems. This part has been designed to work only with a car that is in good state of repair. Pre-existing
problems or faults can result in improper operation and/or failure of your engine. This is your responsibility to
ensure. No matter how carefully we design our Parts, this is one area we have no control over and cannot be held
responsible.
Always use the highest grade of fuel available in your area. This is essential for correct operation of your car and
your new Upgrade parts. Failure to use high-octane fuel can result in engine damage.
Tools Required
Metric Wrench Set
Screwdriver Set
Heavy duty hydraulic Jack and Car Stands
Hacksaw
Die grinder
Metric Socket Set
Pliers
Box knife or similar
WD40
Angle grinder
Kitting List
Note: Check this kit list before starting the install to make that you have all these parts.
LDNXT002 FMIC Core
2 x ABSTA001 8mm flat washer
2 x BOLT-023 8x25mm bolt
8x Bolt-028 45mm bolt
8x ABTHUA01 washer
6x Bolt-005 30mm bolt
6x ABVUA001 washer
2BPHTT01
INT-350 Intercooler spacer
8 x CLAMP-926 60/80 clamp
2 x CLAMP-927 70/90 clamp
2 x MC34C001 50/70 clamp
2 x CLAMP-914 32/50 clamp
HOSE-815 2 1/2” 90deg rubber
elbow
WRX-2001-04 Rubber intercooler
intermediate hose
WRX-2001-01 Turbo rubber
discharge duct
WRX-06 Cut-back hose
WRX-2001-07 Blow-off Valve
hose
WRX-2006-03 Steel intercooler
entry duct
WRX-2001-075 BOV hose
adapter
2 x SH-803 2 1/2” Silicone Hose
3 x WRX-08 Body clips
WRX-2001-045 Steel
intercooler discharge duct
WRX-2006-05 Steel Throttle
entry duct
2 x WRX-09 Speed Nut
1 x L and T Joint hose fitting
WRX-2006-02 Steel
intermediate intercooler pipe
1 x 1/2” Hose Line
Installation
1.
ALLOW THE ENGINE TO COOL DOWN COMPLETELY BEFORE STARTING WORK.
Unclip back half of the airbox (see photos). It is held on via two clips on top
only.
Loosen the clamp holding on the rubber air intake pipe.
You will be removing the entire airbox as this kit will only fit with an AVO
power filter kit or similar.
Unclip air flow meter harness from the airbox.
Remove top half of the airbox. You will need to pull the hoses off the
holder on the side of the airbox, and be careful not to yank on the wiring
to the air flow meter.
Remove the bottom half of the air box by unbolting the two 10mm bolts on
the bottom and third bolt. Pull the front half of the airbox up gently.
Loosen the clamps on the throttle body
hose to the TMIC, and then unbolt the
top mount intercooler from its brackets
There is a bracket on each side of the
TMIC.
Remove the hoses from the hard lines
on the TMIC.
Next, loosen the clamp on the silicone pipe going to the turbocharger
compressor outlet. Pull the TMIC up and off the car.
Remove grill by removing four outer clips (gently prise out the center
button).
Then push down four black clips and gently pull grill forward until the clips
are held down by the grill. Some models have a 3 piece grill, side parts
come off separate. Remove these as well to get to the headlights bolts.
Using a pair of screwdrivers or clip removal pliers, or other similar tools,
push down on the four clips on the inside of both sides of the grill.
Clips are located directly below the indicated access points.
Pull the grill forward to remove.
(Right photo) Once grill has been
removed, remove the upper headlight
bolt. There is two, one per headlight.
(Left Photo): Remove the two bolts at
the front, inside part of the headlight.
Unclip the globes at the rear, and
remove the headlight completely.
Repeat for the other side of the car.
With the top of the bumper now exposed, remove all of the button clips
from along the top of the bumper.
Jack the vehicle up, put jack stands under the chassis rails in the correct
positions. Remove the plastic engine undertray. Remove the two plastic
head screws (Phillips head screwdriver) from the bumper to the inner
fender liners at the front of the wheels. Pull the inner guard back and
remove the final button clip. If your car is fitted with fog lights, unclip the
wiring harness from the rear of the foglights. Remove bumper.
Remove the front foam bumper bar, and then remove the six bolts from the
bumper bar beam. Remove bumper beam from vehicle.
Next you will need to relocate the horn. When relocating the horn, run the
wiring behind the support. Swivel the horn upwards. Next, relocate the
temperature sensor (left side). You will need to drill a new mount hole.
Some models will have two horns, you will need to relocate both horns if
this is the case.
Now it is time to mount the intercooler to the body. Using the bolt and the
bolt spacer provided, mount the intercooler to the support bracket at the
front of the radiator (as in photo).
Make sure to use the bigger spacer when mounting the intercooler.
INT-350 Intercooler spacer
Fit the steel pipes to the intercooler,
using the provided silicone joiners. Bolt
the lower brackets of the intercooler to
the car as well. They will bolt into the
factory holes underneath.
Route pipes through the opening on the left. If the pipe is too close to the
edge even after adjustment, you may need to trim out the hole with a die
grinder. Make sure to put some paint over the exposed edges if you do so.
One tip is to take some vacuum hose or similar and place that over the
edge of the hole, between the intercooler and the metal, to keep it from
rubbing.
Fit the silicone hose onto the compressor outlet of
the turbocharger. Tighten at the turbocharger end
only. Adjust the hose so that it is aimed down
towards the ground.
Then fit second pipe underneath the engine and bolt it to the exhaust
manifold. When fitting the third bracket to the engine, the bracket may
need to be ground off a little to fit to the standard exhaust manifold.
Note: If you have an aftermarket exhaust manifold, then you will need to
fabricate a bracket from the exhaust manifold flange to the bracket on the
supplied fitting.
Fit the 90 degree rubber hose to that
pipe underneath the engine and to the
steel pipe on the intercooler on the right
side of the vehicle. Tighten all the
clamps on this side of the piping.
Loosely fit the throttle body pipe and check for clearance underneath the
join. If extra clearance is required for the pod filter, then remove the throttle
body pipe and fit a larger spacer on the coolant reservoir to create the
necessary clearance.
Fit the throttle body pipe using the supplied throttle body hose and hose
clamps. Take care to ensure that the offset throttle body hose is positioned
correctly.
Fit the bolt and spacer to the pipe bracket and header
tank.
The shorter side of the throttle body hose should be on the
bottom.
Fit the blowoff valve bracket to the intake manifold, then fit the blow-off
valve assembly onto the bracket. Connect up the hoses and tighten the
hose clamps.
Take a few moments to ensure that all hose clamps and joiner hoses are
correctly fitted and tightened, and ensure that the
hood closes with no obstructions. If the air cleaner
touches the hood, increase the clearance for the
throttle body pipe as previously mentioned. If the
hood doesn’t close correctly, you may need to
remove the underside of the hood scoop.
Use the supplied T- and L-fitting, and
60cm of 1/2” hose to connect the hoses
up.
Trim off the ends of the bumper beam to
provide the space for the intercooler.
It is also possible to trim the underneath
portion of the bumper beam so that the
intercooler may fit. It may take several
tries to get it just right, as pictured in the
photos.
For STI owners: Take the original waterspray hose from it’s current
location and reroute it to the front bumper. Vehicles with aftermarket
waterspray systems will need to do the same.
Fit the waterspray nozzles to the front
bumper, using some spare hose to
connect the nozzles. You can see the
positioning in the photos.
The plastic bumper bar (black portion) will need to be modified to fit the
intercooler. Mark it out carefully and use a hacksaw or similar cutting tool
to cut it.
You will need to trim the bumper cover
on the sides of the intake portion to fit
the ends of the intercooler tanks. See
photos for an example.
Some of the undertray may need to be trimmed as well to fit the intercooler piping.
Refit the front bumper skin and connect the waterspray hose to the nozzles. Fit the one-way valve.
Double-check all the connections, the clamps, and other fittings.
Re-fit the undertray and lower the car off of the jackstands.
Check your boost levels and re-tune the ECU for the new setup.
Note: After completion and removing your tools, double check for leaks and any loose fittings. Correct if
necessary. In order to maintain the reliability of your AVOTurboworld upgrade part, you should inspect all
components during the recommended engine servicing schedules; and rectify or replace any damaged
components as necessary.
Job Done-Enjoy your car!
NOTE! – If in any doubt over the operation or installation of your parts contact
AVOTurboworld, or your selling dealer for advice and assistance
in troubleshooting your questions.