Roojai

Old intercooler:

http://img.photobucket.com/albums/v1...ntercooler.jpg

New intercooler:

http://img.photobucket.com/albums/v1...ntercooler.jpg

Not tested yet.

Question:
Will the classic 1997+ underbonnet vent surround for the IC fit this intercooler or do I need to make my own. And if it does fit the IC, is it a bolt on item on the pre-97 cars?

Cheers!

willy

How much work did it take to fit it?
Did you have any problems?

I`m after the same mod on my car.

*****

wah

Yeah more info please very intrested !!!

Greeno

I've also done a similar job on MY93 WRX...

I am getting a custom IC Vent made up by a reputable fabricationist soon, i'll post some pics once i have had it made...although if the later vents work, then that would be alot more sensiable...i like to be different...

Fitting it was'nt that hard, although it was'nt straight forward either, i had a STI 5/6 IC that was already modded to fit in place of my old Slanty IC, With the DV pipe running from the right hand side...straight off the IC...

I needed to cut down the Throttle Body about half an inch to fit the new IC without it rubbing the bulkhead, and i had to buy a larger Turbo to IC pipe as the STI one was too short, but apart from that it's all just a bit of jiggery pokery really...

Anyone thinking of going this route should do so, it's worth it...unless your rich and can go FMIC...

G.

Roojai

I bought my 2002 intercooler from somebody who had taken it off their crashed MY95 subaru so all the piping was there, but I don't think it would be too hard to get the samco pipes to start from scratch.

It's pretty hard to squeeze it in but I managed it fine the first time without triming anything off the throttle body. However it was touching the bulkhead and transmitting alot of noise into the cabin.

I tried again and took about 5mm of the top edge of the throttle body opening, cutting down at an angle so that at the bottom I still had the lip. This helped alot, mainly with being able to squeeze the rubber hosing between throttle body and IC into place. I had to modify the rubber hosing a bit by cutting a slither of that as it was too thick. I also had to modify the clutch fluid container as well.

I am still getting some contact with the bulkhead and noise transmission, but I have constructed and installed a brace tonight on to one side of the intercooler and will do the same to the other side, thus supporting the IC away from the bulkhead. I *may* have to move the brake-assist vacuum pipe as well.

All in all not easy, but hopefully worth it. I can take some pictures and go into more detail this week if helpful

willy

Yes more pics please.

Very helpful

Roojai

OK, all working great now and no unwanted contact or vibrations.

Pictures:
pipe work set up for early WRX that came with intercooler
http://img.photobucket.com/albums/v1...i/pipework.jpg


Modified clutch cylinder (slightly shortened (cut from bottom) and turned away from IC) (note: picture is not the right way up)
http://img.photobucket.com/albums/v1...lutchfluid.jpg

Sawn Throttle body. did it with a hack saw, in place on car. Covered entry to turbo with cling film and cleaned out entrance to throttle body very carefully after, to reduce risk of small metal particles getting into engine.
http://img.photobucket.com/albums/v1...rottlebody.jpg

Metal brake vacuum hose replaced with rubber fuel hosing and run underneath the IC. The part of piping circled in red on left needs to be retaineed as it has a valve in it. I put a rubber bush on the mount mount circled in red to help support the new Intercooler. I also moved the wire conduit below the brake line to under the IC (still in place in photo)
http://img.photobucket.com/albums/v1...vacuumhose.jpg

Intercooler in place showing custom bracket
http://img.photobucket.com/albums/v1.../icinplace.jpg



Areas that you may need to bash down with a hammer to prevent contact with IC pipework giving you nasty noise transmission. Not as difficult as it sounds. Metal is quite soft.
http://img.photobucket.com/albums/v1...tstohammer.jpg



One last thing (no picture), I screwed on some pipe insulating material to underside of bonnet to creat a good seal with the IC. It is important to get a good seal between IC and scoop opening to ensure air runs throught the IC.
You also need to modify the metal underbonnet scoop that goes above the turbo a little (pair of pliers and tin snips)

I have noticed a significant inprovement with this IC from the old one. I had the boost up to 17psi today and not a hint of DET whereas before I might get it at that boost level. Boost seems to come on a bit quicker as well. Power feels great.

dj219957

well done mate!