FRONT MOUNT INTERCOOLER 2008+ Subaru WRX/STi - TurboXS

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FRONT MOUNT INTERCOOLER 2002-
2007 Subaru WRX/STi (WS-FMIC and
WS-FMIC-0607)
Thank you for purchasing the TURBOXS front mount intercooler system for your 2002-2007 Subaru
WRX/STI. Please check the box contents to make certain that you have received all parts and read these
instructions from start to finish before beginning installation. Read the IMPORTANT NOTES section
below carefully before beginning installation.
This document is meant to be used as a guide for an experienced mechanic or car enthusiast
during the installation of the TurboXS WRX/STi Front Mount Intercooler Kit. While the guide
offers a straightforward, step-by-step procedure, it does not go into fine detail on how to complete each
step. The use of factory service manuals is highly recommended. These can be purchased or downloaded
from http://techinfo.subaru.com.
Note that while the kit has been designed to work on MY2002-2007 WRX and STi, most pictures in this
manual were taken during installation of a 2002 WRX.
IMPORTANT NOTES:
• The stock intake system on the 2002-2007 WRX and STi will NOT work with the TurboXS front
mount intercooler. TURBOXS Intake part # WS-INTAKE or similar is required in order to install
that TURBOXS Front Mount Intercooler Kit.
• There is no bumper-support beam needed to install this kit. The bumper support mounts are on
the intercooler core.
Page 1
• Installation of the WS-FMIC and WS-FMIC-0607 will require you to cut out parts of your bumper
in order to fit the intercooler core.
• Fog lights remain intact for both the WRX and STi
Parts Included with the TurboXS Front Mount Intercooler:
Item # Part Description Quantity
1
Front Mount Intercooler Core Assembly w/ integrated
bumper support mounts 1
Intercooler Pipe Kit
2 Pipe 1; Out of Turbocharger 1
3 Pipe 2; Driver Side towards core 1
4 Pipe 3; Core, Driver Side 1
5 Pipe 4; Core; Passenger Side 1
6 Pipe 5; Through Fenderwell 1
7 Pipe 6; Into Throttle Body 1
Silicone Hose and T-clamp Kit
8 Silicone Hoses inside diameter 63mm p/n# SC-63 6
10
Silicone Hose Elbow inside diameter 50 to 63mm p/n#
ER-5163T 1
11 Silicone Hose inside diameter 70mm p/n# SC-70S 1
12 69 to 76 mm Stainless Steel Hose Clamps 13
13 73 to 81 mm Stainless Steel Hose Clamps 2
14 56 to 62 mm Stainless Steel Hose Clamps 1
Accessory Packet
15 “L” Bracket for Pipe #2 1
16 Edge Strip Length 310 mm long 1
14 Fuel Line 5/16” by 250 mm long 1
15 1/2" T-piece 1
16 Washer M8 4
17 Bolt M8 x 16mm 4
19 135mm Long Spring 1
20 Aluminum Plug 1
Miscellaneous Hardware
21 Radiator Overflow Bottle 1
22 1/2" Vacuum Line; 660mm 1
25 TXS RBV-H34 Bypass Valve 1
26 TXS H-90 Elbow Adapter 1
Installation Instructions
Preparation
1. Disconnect the battery.
2. Remove existing Top Mount Intercooler
3. Remove intake system up to turbo inlet hose. This includes removing the rubber intake elbow (2
x hose clamps), airbox (2 x 10mm bolt located on chassis and 1 x 10mm nut on inside of airbox).
4. Remove OEM coolant overflow bottle. Drain coolant into a clean container and save to re-use
later.
Page 2
5. Remove bumper cover from car. Carefully remove all plastic clips holding bumper in place. Two
(2) are not visible and are located behind grill next to the headlights. Once all clips are removed
the bumper is held in place by snaps located under the headlights. Unplug the foglight
connectors – one on each side before removing the bumper. To complete bumper removal, tug
bumper away from headlights. It is very help full to have a second person to complete this step
so you can do both side at the same time.
Intercooler Core Installation
1. Remove bumper support beam by removing the eight (8) x 12mm bolts that attach the beam to
the frame.
2. Remove the three (3) small tabs on chassis using a cut-off wheel. Alternatively, they can be bent
downward with a hammer. There are also two (2) plastic brackets that will need to be removed
or trimmed in order to allow the intercooler core to fit.
3. Install E12-63 silicone coupler to driver side Intercooler Core outlet. Loosely secure with T67-73
T-bolt clamp.
4. Install SC-63 silicone coupler on the passenger side Intercooler Core inlet. Loosely secure with
T67-73 T-bolt clamp.
5. Install intercooler core to bumper beam using four (4) M8 x 35mm bolts. NOTE: Make sure that
the mounting tabs on the bottom of the intercooler core are pointing towards the rear of the car.
Tighten bolts to ~20f-t-lbs.
6. Install supplied intercooler support beam/intercooler core assembly to chassis frame using OEM
bolts. Torque bolts to ~20ft-lbs.
Intercooler Piping Installation
In all installations, five (5) pipes are used to connect the turbocharger outlet to the throttle body inlet on
the intake manifold. However, you will note that your TurboXS 2008+ Subaru WRX/STi FMIC comes with
seven (7) pipes. This is because the WRX and STi have different turbocharger outlets and different intake
manifolds. Therefore, the first pipe (coming off the turbocharger) and the last pipe (going into the throttle
body) will be different depending on whether you are installing this kit on an STi or a WRX. Follow the
instructions below and reference the individual pipe pictures as well as the installation pictures in this
document to determine which pipe goes where.
Page 3
Illustration 2: Pipe 1aIllustration 3: Pipe 1b
Illustration 1: FMIC Core mounted to Bumper Beam
WRX Intercooler Piping:
1. Install Turbo Adapter Flange to Turbocharger. Use silicone RTV on the mating surfaces of the
flange and turbo to seal the joint. Tighten flange bolts to ~14ft-lbs, using OEM bolts.
2. Install ER-5163T2 to outlet of Turbo Adapter Flange. Loosely secure with T55-61 T-bolt clamp.
3. Install Pipe 1a to ER-5163T2 silicone coupler on Turbo Adapter Flange. Loosely secure with T6773 T-bolt clamp.
4. Install SC-63 coupler to outlet of Pipe 1a. Loosely secure with T67-73 T-bolt clamp.
5. Install Pipe 2 between to SC-63 coupler on outlet of Pipe 1a and the SC-63 coupler on the
passenger side Intercooler Core inlet. Loosely secure with T67-73 T-bolt clamp.
6. Install Pipe 3 (u-pipe) to E12-63 coupler on driver side Intercooler Core outlet. Loosely secure
with T67-73 T-bolt clamp.
7. Install E90-63 coupler to outlet of Pipe 3. Loosely secure with T67-73 T-bolt clamp.
Page 4
Illustration 4: Pipe 2 Illustration 5: Pipe 3
Illustration 6: Pipe 5a
Illustration 8: Pipe 5b
Illustration 7: Pipe 4
8. Install Pipe 4 to E90-63 coupler on outlet of Pipe 3. Loosely secure with T67-73 T-bolt clamp.
9. Install SC-63 coupler to outlet of Pipe 4. Loosely secure with T67-73 T-bolt clamp.
10. Install Pipe 5a between SC-63 coupler on outlet of Pipe 4 and factory inlet to throttle body.
Loosely secure with factory hose clamp.
NOTE: LOOSEN AND REMOVE 10MM BOLT SECURING FUEL LINES TO INTAKE MANIFOLD. THIS
WILL HELP ALLEVIATE TENSION ON RUBBER FUEL LINES AFTER INSTALLATION OF THIS PIPE.
INSTALLER IS RESPONSIBLE FOR ADEQUATE CLEARANCE FROM FUEL LINE TO PIPE. FAILURE TO
PROPERLY ALLEVIATE TENSION ON THESE LINES CAN EVENTUALLY WEAR LINES. FIRE, INJURY
AND DEATH CAN RESULT!
11. Bolt factory BOV to flange on Pipe 5a using Silicone Gasket seal and supplied M6 x 30mm
bolts/nuts/washers.
STi Intercooler Piping:
1. Install ER-5163T to outlet of Turbocharger. Loosely secure with T55-61 T-bolt clamp.
2. Install Pipe 1b to ER-5163T silicone coupler on Turbocharger. Loosely secure with T67-73 T-bolt
clamp.
3. Install SC-63 coupler to outlet of Pipe 1b. Loosely secure with T67-73 T-bolt clamp.
4. Install Pipe 2 between to SC-63 coupler on outlet of pipe 1b and the SC-63 coupler on the
passenger side Intercooler Core inlet. Loosely secure with T67-73 T-bolt clamp.
5. Install Pipe 3 (u-pipe) to E12-63 coupler on driver side Intercooler Core outlet. Loosely secure
with T67-73 T-bolt clamp.
6. Install E90-63 coupler to outlet of Pipe 3. Loosely secure with T67-73 T-bolt clamp.
7. Install Pipe 4 to E90-63 coupler on outlet of Pipe 3. Loosely secure with T67-73 T-bolt clamp.
8. Install SC-63 coupler to outlet of Pipe 4. Loosely secure with T67-73 T-bolt clamp.
9. Install SR-6370 coupler to the throttle body inlet on the intake manifold. Loosely secure to
throttle body with T74-80 T-bolt clamp.
10. Install Pipe 5b between SC-63 coupler on outlet of Pipe 4 and factory inlet to throttle body.
Loosely secure hose clamps.
NOTE: LOOSEN AND REMOVE 10MM BOLT SECURING FUEL LINES TO INTAKE MANIFOLD. THIS
WILL HELP ALLEVIATE TENSION ON RUBBER FUEL LINES AFTER INSTALLATION OF THIS PIPE.
INSTALLER IS RESPONSIBLE FOR ADEQUATE CLEARANCE FROM FUEL LINE TO PIPE. FAILURE TO
PROPERLY ALLEVIATE TENSION ON THESE LINES CAN EVENTUALLY WEAR LINES. FIRE, INJURY
AND DEATH CAN RESULT!
NOTE: In order to reinstall the factory Bypass valve on the 2008+ STi you will need to
purchase the TurboXS 2008+ FMIC Bypass Valve Adapter kit (WS08-FMIC-BPV) from
TurboXS.
12. Follow the instructions included with the WS08-FMIC-BPV in order to re-install the factory bypass
valve.
Completing Intercooler Installation (WRX and STI)
Page 5
1. Position each intercooler pipe exactly as you want it making sure each pipe is inserted inside
silicone coupler far enough to allow T-bolt clamps to be positioned behind the raised bead on
each pipe.
2. Tighten all T-bolt clamps. It is best to start from one end and work your way to the other end
to make sure you do not miss any. Loose clamps will result in an intercooler pipe blowing off
under boost. This will likely cause the car to stall.
3. As each clamp is tightened, some adjusting of the remaining intercooler pipes may be necessary
to maintain proper positioning and clearances. Take your time. Trust me, you don’t want to do
this more than once!
4. Remove plastic cap from OEM coolant overflow bottle and snap onto TurboXS Coolant Bottle lid.
5. Install Coolant Overflow Bottle using OEM bolt in the position shown in picture below.
6. Insert OEM coolant hose into TurboXS Coolant Overflow bottle opening. Trim hose length as
needed.
7. Fill coolant Overflow Bottle about half-full using either the coolant from the OEM overflow
reservoir or new coolant.
8. Install appropriate intake system into vehicle. A TurboXS 2008+ Cold Air Intake (WS08CAI) or similar intake is required.
9. Re-connect battery.
10. Start car and make sure the car is idling normally. If it is not, check for vacuum leaks. More
than likely you will have a loose T-bolt clamp that needs to be tightened.
11. Do a final check of pipe positioning and make sure that there is clearance around all the pipes.
The next step is to replace the bumper, so you want to make sure the pipes are in position now
as it is much harder to get at some of the T-bolt clamps when the bumper is back on.
12. A section of the bumper must be cut out in order to reinstall the bumper. Trimming is required
to give enough room for the intercooler core and piping. This is best done with an air powered
cut off wheel. However, it can be done with a utility knife with a fresh blade. Hold the bumper up
to the car to see where you need to trim. It is best to mark the line you want to cut on using
Page 6
Illustration 9: Coolant Overflow Bottle Installed
masking tape. Next, lightly scribe a line with a utility knife with a new blade. Then make
progressively deeper cuts. It is best to do this when the temperature is warm.
13. Disconnect battery.
14. Re-install bumper cover, connect battery and proceed to test drive.
For questions please contact INFO@TURBOXS.COM or
call 301.977.4727.
Page 7

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