Installation Instructions: 08 Subaru STI FM Intercooler
Contents
1. 10DEC08 Ver 01 1 Installation Instructions 08 Subaru STI FM Intercooler Kit Part Number 20005378 Applications 2008 Subaru WRX STI Disclaimer and Warranty A vehicle modified with Cosworth competition and or racing performance products will not meet the legal requirements for operation on public roads and highways It is the purchaser s responsibility to check and comply with all local state and federal laws prior to operating vehicle Installation and use of performance products may also affect and void warranty and insurance policies In general Cosworth Performance Parts carry no warranty Cosworth LLC and Cosworth Ltd shall not be liable for direct indirect incidental or consequential damage or injury to persons or property that might be claimed as a result from the installation improper installation and failure of part including claims for delay loss of profits or labor There are no warranties expressed or implied Index P1 This Page Disclaimer and Warranty P2 Parts List P3 General Information P4 11 Installation P12 Additional tips and warranty Information Parts List 10DEC08 Ver 01 2 Installation Instructions 08 Subaru STI FM Intercooler Kit ITEM QTY DESCRIPTION COSWORTH PART 1 1 Front Mount Intercooler 20004057 2 1 Intercooler Support Beam 20006093 3 2 Intercooler Mounting Bracket 20006459 4 4 Grommet 20006092 5 4 Bung 20004127 6 4 M82. X 1 25 X 20 Bolt PP6578 7 4 M8 X 1 25 x 16 Bolt PP6576 8 8 8 4 X 15 X 2 Washer PP3429 9 4 M8 X 1 25 Nyloc Nut 20006183 10 1 2 5 Flanged Intercooler Tube A 20007763 11 1 2 5 Intercooler Tube B 20007765 12 1 2 5 Intercooler Tube C 20007766 13 1 2 75 Intercooler Tube D 20007779 14 1 2 75 Intercooler Tube E 20007780 15 1 2 75 Intercooler Tube F 20007781 16 1 2 5 to 2 0 Reducer Silicone Coupler 20006156 17 1 2 75 to 2 5 Reducer Silicone Coupler 20006160 18 1 2 5 70 Elbow Silicone Coupler 20006164 19 1 2 75 45 Elbow Silicone Coupler 20006163 20 1 2 75 Hump Silicone Coupler 20006162 21 1 2 5 Straight Silicone Coupler 20006159 22 2 2 75 Straight Silicone Coupler 20006161 23 1 1 75 Max Dia Liner Hose Clamp 20008245 24 1 2 00 Max Dia Liner Hose Clamp 20008246 25 1 2 50 Max Dia Liner Hose Clamp 20006180 26 6 3 00 Max Dia Liner Hose Clamp 20006181 27 9 3 25 Max Dia Liner Hose Clamp 20006182 28 1 Aluminum Reducer 20008088 29 1 Recirculation Valve Hose 20008058 30 1 Windshield Washer Cap 20008130 31 1 Windshield Washer Cap O Ring PP5941 32 1 Tee Pipe Fitting 20006481 33 1 90 Pipe Fitting 20008323 34 1 Crankcase Breather PCV Hose 20008325 35 1 M8 X 1 25 X 20 Button Head Cap Screw PP8182 36 2 M8 X 1 25 x 16 Bolt PP3030 37 3 Zip Tie PP5089 38 1 Installation Instruction sheet 20008295 10DEC08 Ver 01 3 Installati
3. by pulling the sides of the bumper cover away from the fenders 16 Remove the bumper beam by removing the 8 bolts that mount it to the frame 17 Remove and relocate the center horn and bracket To keep the center horn it needs to be relocated after step 29 because it mounts to the outer surface of the Intercooler support beam It may also need to be bent forward slightly to allow for clearance 18 Replace the bolt that mounts the hood latch with the supplied M8 button head screw 19 Remove the ambient air temperature sensor and relocate it to the back surface of its original location 20 Remove the plastic retainer that mounts the windshield washer neck 21 Pull the windshield washer neck from the windshield washer tank pressure may need to be applied to the positive engagement tab to release it Plastic Retainers Ambient Air Temp Sensor M8 Button Head Screw Location New Horn Location Relocate after step 29 Intake Ram 10DEC08 Ver 01 6 Installation Instructions 08 Subaru STI FM Intercooler Kit 22 Install the supplied windshield washer cap Be sure to install the supplied o ring onto the cap prior to installation 23 Remove the plastic retainer that mounts the intake silencer to the airbox 24 Remove the intake silencer It may be necessary to apply pressure to the two positive engagement tabs on either side of the intake silencer s neck 25 Insert the 4 supplied grommets into the 4 larger holes in the
4. Intercooler mounting brackets 26 Insert the 4 supplied bungs into the grommets with the slotted flanges facing upwards 27 Mount the intercooler mounting brackets to the front of the intercooler with the slotted flanges facing inwards 28 Mount the Intercooler to the support beam by aligning the holes in the intercooler mounting brackets with the slots in the intercooler support beam All 8 washers are used here 4 on the outside of the intercooler bracket and 4 on the inside of the intercooler support beam Plastic Retainer and Positive Engagement Tabs Intake Silencer Grommet Bung Bracket 10DEC08 Ver 01 7 Installation Instructions 08 Subaru STI FM Intercooler Kit 29 Install the Cosworth intercooler support beam with the bolts previously used to secure the Subaru OE bumper These bolts have a torque specification of 50 ft lbs The intercooler height may need to be adjusted via the slots in the intercooler bracket to ensure there is not any contact between with the intercooler and bracket Be sure to check the metal seam below the intercooler and the button head cap screw that now secures the hood latch to ensure proper clearance exists 30 Before reinstalling the recirculation valve hose it needs to be modified to accommodate the new location of the recirculation valve Cut the recirculation valve hose at the specified location 31 Insert the smaller end of the supplied aluminum reducer approximately 1 into th
5. This kit is not designed for use on any other vehicles Cosworth does not provide technical support for any other configuration other than intended If you wish to adapt the product to your own application you will have to do so on your own Although the Cosworth front mount intercooler kit can be reconfigured and modified for use with additional aftermarket components such as a different turbo throttle body and or blow off valve these products can alter the fit and function of this kit therefore Cosworth does not offer any type of technical support for set ups using other than OE components Please take a few minutes to inspect and count the parts to ensure there are no signs of damage or missing parts Pay special attention to the flat machined surfaces Additionally make sure that all tubes and the intercooler are free from debris such as packaging material If any of the parts are physically damaged please contact the shipping company to make a claim If you are missing parts and the box was obviously torn or opened then contact the shipping company to make a claim If you are missing parts and the box was fully sealed in Cosworth packaging please contact Cosworth for replacement parts 10DEC08 Ver 01 4 Installation Instructions 08 Subaru STI FM Intercooler Kit Installation 1 Remove the bolts that mount the recirculation valve blow off valve to the OE top mount intercooler 2 Disconnect the recirc
6. e modified recirculation valve hose install the 1 75 max dia liner hose clamp and tighten the hose clamp to 3 75 ft lbs Cut Location 10DEC08 Ver 01 8 Installation Instructions 08 Subaru STI FM Intercooler Kit 32 Slide the supplied recirculation valve hose over the large end of the aluminum reducer approximately 1 into the modified recirculation valve hose install the 2 00 max dia liner hose clamp and tighten the hose clamp only enough to secure the hose It may be necessary to leave the hose clamp loose to adjust the orientation relative to the recirculation valve 33 Reinstall the modified recirculation valve hose to the intake tract with the OE spring clamp Make sure the modified recirculation valve hose is located below the throttle body coolant line 34 Reroute the boost reference hose underneath the modified recirculation valve hose and the drive by wire jacket 35 Install the tubes couplers and hose clamps according to the diagram below 2 5 tubes travel from the turbo to the hot side of the intercooler 2 75 tubes travel from the cold side of the intercooler to the throttle body Hose clamps denoted with a 40 are for use with the 2 5 tubes and hose clamps denoted with a 44 are for use with the 2 75 tubes The recommended torque specification for the hose clamps is 3 75 ft lbs It may be necessary to loosely install all of the tubes and couplers to find the optimal positioning for the intercooler
7. ntercooler tubes Do not over bend or kink these lines damaging these lines or not creating the proper clearances to avoid chaffing may lead to serious injury or death 41 Check for clearances between the intercooler tube and the header tank hoses If clearance does not exist shorten the two hoses that enter the header tank Remove approximately 1 from the longer line and 5 from the shorter line It may be necessary to bleed the coolant system after this modification is complete Refer to the factory service manual for this procedure Shortened header tank hoses Fuel Line Clearance 10DEC08 Ver 01 11 Installation Instructions 08 Subaru STI FM Intercooler Kit 42 Reinstall the recirculation valve onto the flange on intercooler tube A with the two hex head M8 bolts that are supplied The neck faces downwards Be sure to reuse the gasket or replace it with a new one if it appears damaged 43 Reconnect the modified recirculation valve hose install the OE spring clamp and tighten the supplied hose clamp 44 Reconnect the boost reference hose to the recirculation valve it is necessary to route the hose underneath the recirculation valve hose 45 Check for clearances between Intercooler tube and the intake ram If clearance does not exist it is necessary to trim and or deform the intake ram It is recommended to trim the upper part of the intake ram with a razor blade or rotary tool and re shape the intake ram cavity with
8. on Instructions 08 Subaru STI FM Intercooler Kit General Information Congratulations on your purchase of a Cosworth Front Mount Intercooler Kit for the 2008 Subaru WRX STI This front mount intercooler is designed by Cosworth Engineers for higher than stock boost applications able to supply a cooler and denser intake charge than the OE top mount system This kit also achieves minimal pressure loss without an increase in turbo lag Your Cosworth Front Mount Intercooler kit is designed to handle the vigor of drag road endurance and all other forms of racing It is strongly recommended that the Cosworth front mount intercooler kit is installed by an experienced tuning shop or mechanic To maximize horsepower and torque gains we recommend having your engine professionally tuned and calibrated by an experienced tuning shop after installation is completed This Cosworth front mount intercooler kit is not legal for use on pollution controlled vehicles that will be operated on US highways Please check your local laws for your regulations Specific applications 2008 Subaru WRX STI This manual is designed as a guide to explain the intricacies and details for the installation of the Cosworth front mount intercooler kit Once assembled it will replace the OE top mount intercooler Please refer to the factory service manual for all other removal and installation procedures of factory components not covered in this manual
9. re are no warranties expressed or implied Disclaimer A vehicle modified with Cosworth competition and or racing performance products will not meet the legal requirements for operation on public roads and highways It is the purchaser s responsibility to check and comply with all local state and federal laws prior to operating vehicle Installation and use of performance products may also affect and void warranty and insurance policies
10. the use of a heat gun or other heat source 46 Insert the supplied tee fitting into the passenger side OE crankcase ventilation hoses connect the supplied crankcase ventilation hose to the open end of the tee fitting 47 Connect the 90 fitting to the open end of the supplied crankcase ventilation hose and connect the fitting to the driver s side OE crankcase ventilation hose 48 Close the hood to make sure there is clearance between the intercooler tubes and the hood If clearance does not exist adjust the intercooler tubes accordingly 49 Check to make sure all hose clamps are tightened and all of the proper clearances exist Routine checks should be made to ensure the longevity of this kit 50 Reattach the front bumper by reinstalling the 18 plastic retainers that were removed There should not be any interference with the Intercooler or associated tubes Trim Tee fitting 90 fitting Heat and Re shape OE PCV hoses Supplied Hose OE PCV hose 10DEC08 Ver 01 12 Installation Instructions 08 Subaru STI FM Intercooler Kit Warranty In general Cosworth competition and or performance parts carry no warranty Cosworth LLC and Cosworth Limited shall not be liable for direct indirect incidental or consequential damage or injury to persons or property that might be claimed as result from the installation or improper installation and failure of part including claims for delay loss of profits or labor The
11. tubes before tightening the hose clamps Check to make sure all tubes and couplers are free of debris prior to installation 10DEC08 Ver 01 9 Installation Instructions 08 Subaru STI FM Intercooler Kit 36 The underbody splash tray and fender splash tray on the passenger side need to be trimmed to allow the intercooler tubes to pass freely under the frame 37 Check for clearances between the 2 75 70 coupler and the passenger side horn If clearance does not exist bend the passenger side horn bracket back to allow for clearance 38 Check for clearances between the 2 75 hump coupler and the passenger side headlight wires If clearance does not exist disconnect the p clip that secures the head light wires on the passenger side It may also be necessary to trim the excess material on the p clip and or zip tie the wire back to the bracket 39 Check for clearances between the intercooler tube and the air conditioning line If clearance does not exist gently bend the aluminum air conditioning lines away from the intercooler tubes and secure the hose to the alternator wire jacket with the supplied zip tie Zip Tie Bent AC line Disconnected P clip Trimmed Splash Trays Bent Horn Bracket 10DEC08 Ver 01 10 Installation Instructions 08 Subaru STI FM Intercooler Kit 40 Check for clearances between the intercooler tube and the fuel lines If clearance does not exist gently bend the fuel lines away from the i
12. ulation valve hose and boost reference hose from the recirculation valve 3 Remove the recirculation valve 4 Disconnect the crankcase breather hoses that mount to the hard lines at the front of the OE front mount intercooler 5 Loosen the clamp around the red hose that attaches the intercooler to the turbo 6 Loosen the clamp around the black hose that attaches the intercooler to the throttle body 7 Remove the bolts that mount the intercooler there is one bolt located on each side of the intercooler 8 Carefully remove the OE top mount intercooler from the engine bay 9 Disconnect the recirculation valve hose from the intake tract It may be necessary to temporarily remove the throttle body to access the spring clamp Recirculation Valve Bolts Recirculation Valve Boost Reference Recirculation Valve Spring Clamp Throttle Body Hose Clamp Turbo Hose clamp PCV lines 10DEC08 Ver 01 5 Installation Instructions 08 Subaru STI FM Intercooler Kit 10 Remove the plastic retainers that mount the intake ram to the upper radiator supports 11 Carefully pull the intake ram away from the airbox 12 Remove the 4 plastic retainers that mount the top of the grill to the upper radiator support 13 Remove the 8 plastic retainers that mount each side of the front bumper cover to the fenders 14 Remove the 6 plastic retainers that mount the front bumper cover to the splash tray 15 Carefully remove the front bumper cover
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