Congratulations on your purchase of the COBB Tuning Front Mount Intercooler Kit. The following instructions will assist you through your installation process. Please read them first BEFORE beginning the install and familiarize yourself with the steps and tools needed. If you feel that you cannot properly perform this installation, we HIGHLY recommend you take the vehicle to a qualified and experienced automotive technician.
IMPORTANT! Installing this kit will require custom tuning or utilizing an appropriate Stage Power Package map. Please consult with COBB or an authorized ProTuner in your area.
On the underside of the front bumper, remove (11) push clips - (9) bottom, (1) driver side, (1) passenger side.
On the top side of the front bumper, remove (3) push pins, and (6) 10mm bolts. Remove the black trim/weatherstripping.
Release pressure clips on each side by the wheel arches by applying a small about of pressure outwards. Gently pull the front bumper away from the car. It helps to have (2) people here. Not much force is required.
As you remove the bumper, be wary of the foglight harness connectors on both the driver and passenger side. You have enough length in the harness to gently set the bumper down while you disconnect the harness.
Remove the bumper beam. There will be (8) 12mm bolts bolts - (4) on each side.
Flip horn orientation as depicted.
Remove bottom rubber hose. Be warned, washer fluid tank will begin to drain. Use 1/4 or 6mm rubber cap to plug it. Gently tie off the hose.
Remove the (3) 10mm bolts off of washer reservoir. You will need a 12"+ extension for the rear bolt.
Disconnect the electrical harness and retention clips.
Remove (1) bolt, 10mm, holding on wheel well tray
Remove washer fluid level sensor.
Remove reservoir.
Twist and pull reservoir spout from main tub.
Remove the o-ring and place it on the new washer fill hose tank adapter.
Twist and install new adapter to main tub.
Install (3) spacers using stock hardware, make certain to orient the spacer vertical with the empty thread slot on the top side.
Install washer fluid reservoir onto the spacers using the supplied hardware, (2) 10mm bolts and (1) 10mm nut. You will need a 12"+ extension for the rear bolt.
Clip the washer fluid level sensor back in, connect washer fluid line back to tank, and connect washer fluid motor harness.
Fill reservoir with fluid.
Using the supplied hardware, (4) 12mm bolts, (4) 12mm nuts, install the provided bumper beam to the COBB FMIC core.
Reusing the OEM hardware, (8) 12mm bolts, install the bumper beam and attached FMIC core to the car.
Remove driver side intercooler bracket which is held on by (2) 12mm bolts.
OPTIONAL: Remove the remaining portion of the driver's side intercooler bracket by removing the (3) 12mm bolts. This is not necessary for clearance, and it's an absolute pain to remove.
Remove both vacuum hoses from the coolant reservoir.
NOTE: Fluid will likely leak. You will likely want a rag for cleanup/catch.
NOTE: Please make certain that the car is cool to the touch prior to doing this to ensure pressure has been discharged.
Note the writing on each vacuum hose and cut them accordingly.
Cut the outer vacuum line 1.25".
Cut the inner vacuum line 0.75".
Reconnect the vacuum lines.
Remove the 10mm bolt holding the vacuum hose bracket.
Remove the plastic hose guide and transfer it to the provided bracket.
Insert provided rubber grommet into the bracket.
Press the provided aluminum bushing into the bracket.
Remove the remaining 12mm bolt holding the coolant reservoir to the manifold.
Insert the provided spacer between the reservoir and the manifold and tighten back down.
Insert bracket between manifold and reservoir and tighten it down using the original (1) 12mm bolt.
Collect the parts needed for the hot side intercooler piping:
(1) 3" - 2.5" reducer
(2) 2.5" coupler
(1) 2.5" - 2" elbow reducer
(6) #44
(1) #48 - intercooler
(1) #40 - turbo
(1) lower hot pipe
(1) mid hot pipe
(1) upper hot pipe
Install a 3" - 2.5" silicone reducer to the intercooler inlet using the #48 and #44 clamp loosely.
(1) 3"-2.5" reducer
(2) 2.5" coupler
(1) 2.5"-2.75" reducer
(1) 35mm BPV coupler
(1) #48 clamp - intercooler
(7) #44 clamp
(2) #20 clamp - BPV
(1) lower cold pipe
(1) mid cold pipe
(1) upper cold pipe
Install a 3" - 2.5" reducer using a #48 clamp loosely.
Install a 2.5" coupler on the lower cold pipe usuing a #44 clamp loosely.
Attach the lower cold pipe to the FMIC intercooler using a #44 clamp.
Install a 2.5" coupler on the mid cold pipe using a #44 clamp loosely.
Install the provided rubber grommet and aluminum bushing into the bracket on the mid cold pipe.
Remove the metal bracket attached to the headlight harness to allow for more clearance. There is a small Phillips head screw that you will need to remove. Then, there is a clip to release the bracket from the harness. You can use a flathead screwdriver to assist in releasing the clip.
Using a provided zip tie, secure the harness.
Attach the mid cold pipe to the lower cold pipe using a #44 clamp loosely.
Install a 2.5"-2.75" reducer to the upper cold pipe using a #44 clamp loosely.
Use teflon tape or thread sealant to attach the provided bung to the upper cold pipe, 5/16" hex key.
Attach the upper cold pipe to the to the turbo and mid cold pipe using (2) #44 clamps.
Attach the BPV adapter to the 35mm coupler using (2) #20 clamps.
Attach the assembled BPV adapter to the upper cold pipe.
Attach the BPV to the BPV adapter reusing your OEM BPV gasket and hardware, M8 12mm head.
NOTE: You may need to rotate the BPV to align it with the adapter for an easier install.
Attach the foglight harness connectors on both the driver and passenger side.
COBB Product Install Instructions for Subaru Vehicles
Main Installation Instruction Repository for Subaru Parts
Calibration Map Notes for Subaru Vehicles
Link to Subaru Map Notes to see what map you should be on given the parts you've added