SUBFMIC001BK and SUBFMIC001SL - Subaru STI Front Mount Intercooler Installation Instructions
Table of Contents
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.
Parts List
- 1 x Intercooler Core
- 1 x Bumper Beam
- 4 x 12mm Bolt
- 4 x 12mm Nut
- 1 x Coolant Overflow Reservoir
- 1 x Coolant Overflow Reservoir Bracket
- 2 x M6x16 Flange Head Bolt
- 1 x M6x25 Flange Head Bolt
- 1 x T-Fitting
- 1 x 90 Degree Fitting
- 1 x Upper Hot Pipe Support Bracket
- 1 x M6x20 Bolt
- 1 x 2' Vacuum Hose
- 1 x 6" Vacuum Hose
- 1 x Washer Fluid Reservoir Adapter
- 1 x Washer Fluid Reservoir Silicone Extension Hose
- 1 x Washer Fluid Reservoir Silicone Cap
- 3 x Spacer
- 2 x 10mm Bolt
- 1 x 10mm Nut
- 2 x Aluminum Bushing
- 2 x Rubber Insert Bushing
- 3 x Zip Ties
- Hot Side Piping
- 1 x 3" - 2.5" silicone reducer
- 2 x 2.5" silicone coupler
- 1 x 2.5" - 2" silicone elbow
- 6 x #44 clamp
- 1 x #48 clamp
- 1 x #40 clamp
- 1 x lower hot pipe
- 1 x mid hot pipe
- 1 x upper hot pipe
- Cold Side Piping
- 1 x 3" - 2.5" silicone reducer
- 2 x 2.5" silicone coupler
- 1 x 2.5" - 2.75" silicone reducer
- 1 x 35mm silicone coupler
- 1 x #48 clamp
- 7 x #44 clamp
- 2 x #20 clamp
- 1 x lower cold pipe
- 1 x mid cold pipe
- 1 x upper cold pipe
Tools Needed
- Flat Head Screwdriver
- Phillips Head Screwdriver
- Trim Removal Tool
- 10mm 3/8" Socket
- 12mm 3/8" Socket
- 3/8" Ratcheting Wrench
- 3/8" 18" Socket Extension
- 12mm Socket Screwdriver (Optional)
- 10mm Socket Screwdriver (Optional)
- Diagonal Cutters or Scissors; (Hose Cutting tools suggested for straightest cuts)
- 5/16" Hex Key
- Safety Glasses
- Gloves
- Rags
- Silicone Spray or Similar
- Windshield Washer Fluid and Water Repellent Additive
- WRX 2002 - 2007
- WRX STI 2004 - 2020
- Forester XT 2004 - 2008
- Locate your stock bypass valve.
- Using a pair of pliers, remove the return line from the bypass valve.
- Remove the vacuum line from the factory bypass valve.
Using a 12mm socket with ratchet, remove the 2 bolts that hold the bypass valve in place and remove it from the car.
TIP: Make sure to keep an eye on the factory gasket behind the BPV. It can fall when you remove the valve and end up in difficult to reach locations!- Remove the bypass valve.
- Remove breather tubes from intercooler. Dikes can be helpful when removing the metal clamps or zip ties.
- Loosen the turbo outlet clamp using a screwdriver or appropriately sized socket (Typically 7-8mm) along with the (2) throttle body clamps using a screwdriver or 8mm socket.
- Gently wiggle TMIC free from engine bay by sliding it back and then out. Be careful to not damage your windshield wiper cowl.
Removal of the Front Bumper
- Inside the passenger's side front wheel well, remove the (3) push clips using a flathead screwdriver.
- Inside the driver's side front wheel well, remove the (3) push clips using a flathead screwdriver.
- Remove the (3) 12mm bolts holding the undertray on.
- Remove the (2) plastic clips on the rear of the undertray, located near the transmission. The undertray is now free to remove.
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.
Windshield Washer Fluid Reservoir Relocation and Coolant overflow
- Install the COBB coolant Reservoir per the instructions 800660 - VA WRX, STI Coolant Overflow Tank
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.
Install New Bumper Beam
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.
Install Hot Side Intercooler Piping
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.
- Install a 2.5" coupler to the curve end of the lower hot pipe using #44 clamp loosely.
- Attach the lower hot pipe to the coupler on the intercooler using #44 clamp loosely.
- Install a 2.5" coupler to the mid hot pipe using a #44 clamp loosely.
- Attach the mid hot pipe to the lower hot pipe (90 degree bend) using a #44 clamp loosely.
- Install a 2.5" - 2" elbow reducer to the hot side of the turbo using a #40 clamp loosely.
- Install a 2.5" coupler to the mid hot pipe using a #44 clamp loosely.
- Attach the upper hot pipe to the mid hot pipe using (2) #44 clamps loosely.
- Using the included M6x20 bolt, attach the upper hot pipe to the coolant reservoir bracket using a 10mm socket.
- At this point, verify clearance and tighten everything until it's secure.
- Reinstall the OEM intake snorkel using the original (2) push pins.
- install the SF Intake Airbox lid using the original (4) M2.5 bolts and Allen wrench.
Install Cold Side Intercooler Piping
- Collect the parts needed for the cold side intercooler piping:
(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.
- At this point, verify clearance and tighten everything until it's secure.