712650, 724650, 733650, 771650, 7C7650 – COBB Tuning XLE BPV

Multiple platform variants

Congratulations on your purchase of the COBB Tuning XLE Bypass Valve! The following instructions will assist you through the installation process. Please read them BEFORE beginning the install to familiarize yourself with the steps and tools needed. If you feel 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 if you have a matching mechanical configuration. Please consult with COBB or an authorized ProTuner in your area if you have any questions!

Parts List

Parts will vary based on platform

Tools Needed

Phillips head screwdriver
Flathead screwdriver
3/8" ratchet
3/8" 10mm socket
3/8" 12mm socket
3/8" 8mm socket
3/8" 12" extension
3/8" 6" extension
Pliers
3mm Allen Key
4mm Allen Key
13mm Open End Wrench
Moly-Based Grease (We recommend ARP Ultra-Torque Fastener Assembly Lubricant, P/N 100-9911)

Removal of Stock BPV

The COBB Tuning Bypass Valve is meant to be used as a bypass valve. All the cars this product was designed to work on are MAF sensor vehicles. Using it as a blowooff valve (e.g. not recirculating the air back into the inlet) on any vehicle is undesirable due to the affect it will have on the car's operation.

Locate your stock bypass valve.
Using a pair of pliers, remove the return line from the bypass valve.
Remove the vacuum line.
Using a 10mm or 12mm socket with ratchet or 10mm or 12mm open end wrench (depending on application) and remove bypass valve.

Installation of COBB Tuning XLE Bypass Valve

Test fit the COBB Bypass Valve by placing it on the flange and make sure the base and body are in the correct orientation. If you need to change the base and body orientation, please refer to the disassemble and reassemble of the COBB BPV at the end of these instructions.
LGT/08+WRX and Mazdaspeed3 owners, place the provided paper gasket or O-ring on the base of the COBB Bypass Valve and place it on the car's mounting flange. If you did not receive a paper gasket or oring with your COBB BPV (02-07 WRX, STi, FXT, GTR), make sure the stock gasket is in place and place the COBB BPV on the flange.
Attach the COBB BPV reusing the stock bolts. Torque to 12 ft/lbs.
Reattach the stock vacuum line to the barb on the BPV body.
Reattach the stock return line to the nose on the COBB BPV
If you choose to alter the noise of the BPV you can remove the backing plate using a 3mm allen key. This will allow some of the air to be released to the atmosphere

Adjusting Spring Preload

In order to adjust the spring tension on the COBB Tuning BPV adjust the set screw in the top of the BPV body.

Loosen the jam nut using a 13mm open end wrench
Using a 4mm allen key, turn the screw clockwise to increase spring tension, increase the chance of compressor surge and make the BPV vent air slower. This will also cause the BPV to vent later when you lift your foot off the throttle.. Turning the screw counter clockwise will decrease spring tension, decrease compressor surge and make the BPV vent faster. This will also cause the BPV to vent sooner when you lift your foot off the throttle.

NOTE: Adjusting the spring tension does NOT adjust the amount of boost the BPV will hold. In order to adjust the amount of boost the BPV will hold, a stiffer spring will be needed.

Bypass Valve Maintenance

It is recommended that every time you change your oil you inspect your COBB Tuning Bypass Valve to make sure the piston is still moving freely. You can do so by unbolting the BPV from the vehicle mounting flange and pushing on the piston. If you can feel some resistance, it is advised to remove the piston from the body and clean and re-grease the piston, we recommend ARP Ultra-Torque Fastener Assembly Lubricant, P/N 100-991 1, but any moly-based grease will work fine.

Disassemble the COBB Tuning Bypass Valve
In order to remove the piston, unbolt the base flange from the body using a 3mm allen key. Depending on the BPV model you have, this may be 5-6 socket head cap screws. When removing the piston, be careful to not cut the o-ring. If your O-ring is damaged, you can contact COBB Tuning for a replacement.
To reassemble the BPV, push the piston back into the body, so that the piston does not protrude from the body. You can hold the piston at that point by placing your finger over the vacuum connection.
Place the base flange onto the body and re-clock the flange. Secure the flange with the 5-6 socket head cap screws, depending on the model, using a 3mm allen key.