Not a basic and easy job but it's fairly straight forward & I'll run through the process in the order that I find easiest.
My engine is a revision D EJ208
There may be differences in model revisions that I am unaware of but you should be able to work with this DIY.
If you have additional information, methods or techniques that you feel may assist this DIY please feel free to chime in.
Also note that I have used a couple pics from other forums and thanks goes out to the people who originally posted those pics.
Tools needed
8mm socket
12mm socket and ratchet with medium extension bar
Large & medium flathead/phillips head screwdriver depending on your hose clamps
Pliers
Tips
I lay a folded up blanket across the the top of the engine for a padded surface to lay the intercooler on once it is off & flipped upside down.
Be careful not to damage the fins or bang the intercooler around.
If you need to remove the intercooler entirely from the engine bay you should label the vac line that connects to the actuator.
The other three lines that connect to under the intercooler may be repositioned in any order but I wrap a piece of tape around them to keep them together and out of the way.
The vac lines under the intercooler.....
The actuator on the secondary inlet side....
Getting started
If you have a strut bar you may need to remove it for access.
01) Remove the two mounting bolts on both sides of the intercooler 2x12mm
02) Remove completely the passenger side intercooler support bracket attached to the intake manifold 2x12mm
03) Remove the clip to free the vac lines from the intercooler shroud.
03) Remove the clip to free the vac lines from the intercooler shroud.
04) Loosen the main inlet hose clamp connected to throttle body 8mm pipe clamp.
05) Loosen the driver side intercooler plastic hose connecting to secondary turbo, 8mm hose clamp.
05) Loosen the driver side intercooler plastic hose connecting to secondary turbo, 8mm hose clamp.
06) Loosen slightly the driver side intercooler plastic hose connecting to under the intercooler, 8mm hose clamp. (Just loose enough for it twist but tight enough for it to stay on the intercooler pipe)
07) Loosen the passenger side intercooler plastic hose connecting to the primary turbo, 8mm hose clamp.
08) Loosen slightly the passenger side intercooler plastic hose under the intercooler, 8mm hose clamp. ( As before, just loose enough for it twist but tight enough for it to stay on the intercooler pipe)
09) Remove the hose and vac line from the recirc valve or BOV at the front of intercooler (spring clip or hose clamp)
10) Wiggle and pull upwards the intercooler on the passenger/primary side until the plastic hose pops off the primary turbo outlet and the main throttle body hose is clear of the throttle body. Then the intercooler should lift out.
10) Wiggle and pull upwards the intercooler on the passenger/primary side until the plastic hose pops off the primary turbo outlet and the main throttle body hose is clear of the throttle body. Then the intercooler should lift out.
11) Carefully lift and flip the intercooler being mindful of the connecting vac lines underneath.
12) Remove and label the vac line to the actuator on the aluminium secondary inlet pipe if necessary.
Secondary turbo driver side.....
Primary turbo passenger side....
Tips for installation
Refitting can be difficult. It's fiddly and can test the patience of even the most experienced mechanic. Just persevere and think logically, if it's not working out for you there is a reason and you need to find it.
Be gentle or you will be up for new plastic pipes that connect to the turbos. They're an expensive Subaru only part and easy to destroy.
If it isn't going on, don't force it! Remove and inspect the pipes to see if they are round and haven't been bent or creased out of shape.
The best thing you could do to make installation easier is to replace the throttle body hose with a silicone one. Highly recommended to assist installation. It makes installation so much easier. Trust me on this!
You'll need a 2.75 inch silicone joiner and you may need to trim it to the same shape of the removed joiner with a sharp knife.
Some people use a smear of oil on the inside of the plastic pipes to assist them sliding onto the turbos. If you take my advice and get a silicone throttle body hose you won't need to. I actually prefer to keep the connections clean so they seal perfectly and I use wax and grease remover to remove any oil inside the pipes before installing them to prevent any chance of them popping off under boost.
Installation
It's pretty much the reverse order of removal.
The plastic pipes should be still attached to the intercooler and you should be able to rotate them on the aluminium intercooler connections. You don't want them to come off during the installation process so tighten the clamps just enough to allow some movement.
Make sure the 3 vac hoses are connected underneath the intercooler.
Get the intercooler roughly in place, align the primary pipe connection, then connect the pipes in the order of ...
Primary turbo (passenger side)
Throttle body (Middle)
Secondary (Driver side) This will take some manipulation but there is a flexi join on the pipe to allow for this.
Make sure all the hose clamps on the turbo to intercooler plastic fittings are in a position where you can actually tighten them.
Check that the intercooler outlet hose onto the throttle body is fitted ok and then the plastic pipes to the turbo outlets are still in place and on the turbo as far as they can go..
Tighten the throttle body clamp first checking all pipes are in position as move to the next pipe for tightening.
Tighten up all 4 hose clamps on the 2 plastic turbo to intercooler pipes under the intercooler.
Refit the passenger side support bracket and attach loosely to the manifold. 2x 12mm.
Bolt in the intercooler support bolts 2x12mm
Refit the passenger side support bracket and attach loosely to the manifold. 2x 12mm.
Bolt in the intercooler support bolts 2x12mm
Now tighten the bracket onto the manifold.
Refit the recirc hose & spring clip/hose clamp.
Attach the "labelled" vac line to the actuator on the aluminium secondary inlet pipe.
I now like to tighten up the hose clamps with the 8mm socket 1/4 to 1/2 a turn. Tighten them too much and they will snap.
Done & Done.
If you get stuck or have any questions feel free to drop me a PM.
Cheers, WhiteJoshBossKong
