2002-2007 Subaru Impreza WRX/STI Front Mount Intercooler

1) Raise hood and disconnect battery.
2) Remove existing intercooler by removing (2) 12mm bolts, and (2) hose clamps. Remove Throttle Body Coupler. (1) hose clamp.
3) Remove intercooler support brackets, (2) 12mm bolts on drivers side bracket, and (2) 12mm bolts on passenger side bracket.
4) Remove intake system up to turbo inlet hose. This includes removing the rubber intake elbow (2 hose clamps), filter box (2 12mm bolt located on chassis), and resonator box (2 10mm nuts). Resonator box can be better reached when bumper is removed.
5) Remove coolant overflow tank (either 2 10mm bolts, or one clip) from radiator & drain into suitable container. NOTE: Coolant will be reused later.
6) Remove bumper cover and upper grill by removing all pop-it connectors. Most all clips are visible, but some are hidden.
Hidden Clips:
• 02-03 cars have connectors behind headlights and inside of wheel well, that are not seen
• 04-05 cars have connectors behind fog lights and inside of wheel well that are not seen.
• 06-07 cars have connectors behind upper grill and inside of wheel well, which are not seen.
7) When removing bumper, make sure to unplug fog lamps. Fog lamps will not be reused on 2002-2005 cars. 2006+ cars can retain fog lights with slight modification to fog lights. Contact your Subaru dealer for fog light covers if needed.
8) Remove OEM bumper support beam: (4) 14mm nuts, (2) 14mm bolts and (2) 12mm bolts attach beam to chassis.
9) 2006-07 cars: Remove window washer tank from driver’s side of car, this will be installed later steps.
10) Attach correct sized couplers to intercooler core using supplied clamps.
11) Loosely install intercooler core to support beam making sure larger outlet of intercooler core rests on passenger side of the vehicle. Spacers may have came installed between bumper beam and core, make sure to reuse these. Failure to do so will void warranty.
12) Bend down the metal seam at bottom of radiator core support. Remove spot welded nuts from seam by cutting off with tin snips or angle grinder.
13) Install supplied bubble on top rubber molding to metal seam. Failure to install this item can cause damage to intercooler core and hoses!
14) Install intercooler/support beam using hardware removed previously. Torque 14mm bolts 50ft-lbs. Note: There are two sets of holes that allow the beam to be mounted higher or lower. Mount the beam lower for 2002-03 & 2006 cars, and high 2004-05 cars need the beam mounted higher.
15) Tighten 3/8” bolts securing Intercooler to bumper beam to 20ft-lbs. Over tightening can cause failure of Intercooler tabs.

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