Intercooler removal / Throttle body hose install

kts262 · 05-25-2006, 03:42 PM

A lot of people who have to remove the stock TMIC may not be sure how to do it. I know I had no clue how to remove it at first, if it hadn't been for a friend who owned a WRX I'd still be trying to figure out how to remove it. I was installing a red silicone STi throttle body hose to bling out the engine bay a bit so I took some photos and figured I'd write up an intercooler removal too.

Tools needed

- Flat head screw driver
- 12mm socket, socket wrench + extension

1. Take a flat headed screwdriver and loosen the 2 hose clamps tying down the throttle body hose.

2. Remove the 2 12mm bolts connecting the stock bypass valve (or BOV) to the intercooler.

3. Remove the 12mm bolt holding the intercooler to the bracket on the driver's side (in yellow.) Also disconnect the hose connected to the black metal pipe (pointed to in blue.)

4. Remove the 12mm bolt holding the intercooler to the bracket on the passenger size (in yellow.) Also disconnect the 2 hoses connected to the black metal pipes (pointed to in blue.)

5. Loosen the hose clamp that connects the intercooler Y-Pipe to the turbo with a flat-head screwdriver.

6. Shake and pull on the intercooler a bit to loosen it and remove it from the turbo and throttle body. If you have a front strut bar you may have to remove it to get the intercooler out. I did to give me some more working room.

7. This is what you're left with.

Now you can do whatever you need to do. I installed the STi red silicone throttle body hose. It just slipped on easily. Here was my end result:

To re-install the intercooler:

1. To reconnect the intercooler to the turbo and the throttle body, position the Y-Hose next to the turbo and slip it on. Slide it back and forth until it's mostly on and then position the intercooler so you can slide it back over the throttle body hose. Push it on and it should slide back into place perfectly.

2. For the rest of reconnecting everything, reverse the steps above.

TRM 23-AUG-2006: added to the How-To catalog sticky

supermarkus · 05-25-2006, 03:53 PM

Nice write up, if you want to use a socket on those hose clamps I believe they are 8mm bolts.

JJ18Sniper · 05-25-2006, 10:24 PM

Should sticky this for some folks.... Question for you as well: Have you had issues getting the turbo to intercooler red hose to stay on tightly? Mine seems to enjoy moving over time even when tightened down by the clamps.

JKonquer · 05-26-2006, 01:03 AM

what's the best way to connect y pipe hose to turbo? its very hard to get to and just wondering what's the easiest way to do it. mine is not in all the way, maybe 5mm space to the end.

**jsh139** · 05-26-2006, 05:44 AM

I found that if you can't get the turbo to y-pipe hose back on the turbo outlet, it is alot easier to take off that hose from the y-pipe, and put it on the turbo-side first. Then, hold the hose as you slip the intercooler y-pipe onto it. You have more room for your hands if you do it this way. I have medium sized hands, and I couldn't fit them under the turbo to help guide the hose onto it.

Just a thought.

Recyclebiz · 05-26-2006, 06:01 AM

A quick word of advice - this will make it much easier to reinstall. Note the two bolts in the extreme lower left corner of picture #3. Remove them and take the bracket off as well. It'll give you a lot more "wiggle room" when you are trying to get the inlet hose back on to the turbo.

Regards - Recyclebiz

kts262 · 05-26-2006, 06:46 AM

Quote:

Originally Posted by JJ18Sniper

Should sticky this for some folks.... Question for you as well: Have you had issues getting the turbo to intercooler red hose to stay on tightly? Mine seems to enjoy moving over time even when tightened down by the clamps.

I've never had an issue with it. The first time I re-installed the intercooler it took FOREVER to get that red Y-pipe hose to fit onto the turbo but last night when I did this it slipped on easily the first time (which I then had to remove since I forgot to put the hose clamps around the intercooler -> throttle body hose) and the second time it took a big more work but once I got it on there and then slid the intercooler down so it was around the throttle body hose everything lined up perfectly.

I checked the hoses when I got into work this morning and everything is just fine. I'll take a peek over the weekend when I drive around and if anything has changed.

kts262 · 05-26-2006, 06:50 AM

Quote:

Originally Posted by JKonquer

what's the best way to connect y pipe hose to turbo? its very hard to get to and just wondering what's the easiest way to do it. mine is not in all the way, maybe 5mm space to the end.

I just fit part of the hose around the turbo and then rocked the intercooler back and forth a bit and it fit mostly on. Then I positioned the intercooler to get it on the throttle body hose, rocked it around a bit and then it just fell into place and both the Y-pipe hose and the throttle body hose were connected properly.

You can try to loosen up some of the bolts and rock the intercooler around a bit to see if you can close some of that gap. When I reinstalled my intercooler after my TBE install in Sept there was a tiny gap (less than 1/2 a mm) and there were no problems. After last night there is no gap at all. Shifting/rocking the intercooler around should help get it to fill that 5mm gap you have.

The first time I removed the intercooler it took a while and it was a pain to get the Y-pipe hose onto the turbo, but now it's gotten a lot easier to reinstall.

lokutus1 · 05-26-2006, 08:35 AM

nice write-up!

sebtarta · 05-26-2006, 08:45 AM

Nice write up!!

Now when installing the IC best way is adding some oil just a dab (sp?) on the hose in order to help it slid in better to the turbo and throttle body.

kts262 · 05-26-2006, 09:06 AM

Quote:

Originally Posted by sebtarta

Nice write up!!

Now when installing the IC best way is adding some oil just a dab (sp?) on the hose in order to help it slid in better to the turbo and throttle body.

Thanks.

You could dab some oil on there if you feel the need to, I didn't need to since they slipped back on pretty easily for me. If you are just reinstalling the intercooler and reusing the stock Y-pipe hose and the stock throttle body hose there should already be some oil on both as some oil does get into those parts of the intercooler from normal driving (which is why some people install catch cans.)

sti_rules · 11-28-2006, 05:06 PM

Yes, a dab of oil and they slip on like buttah!

DieselClown · 12-01-2006, 06:41 AM

hey guys....are the pics loading up for you? they aren't for me!

kts262 · 12-01-2006, 09:30 AM

You must have some web filter software installed at work that doesn't like my image host.

I'm moving to a new host soon. Check it out from home for now.

EarTears · 12-27-2007, 01:05 PM

I can't view your pics either and I am not behind any web filtering. Could you possibly upload them to another server? It would be greatly appreciated!

05-25-2006, 03:42 PM	#1
kts262 HowTo Contributor Car: 2008 DGM (BBS+Navi) Fav Mod: stock FTL? Location: College Park, MD Posts: 2,087 Join Date: Jan 2005 Trader Rating: (7)	Intercooler removal / Throttle body hose install A lot of people who have to remove the stock TMIC may not be sure how to do it. I know I had no clue how to remove it at first, if it hadn't been for a friend who owned a WRX I'd still be trying to figure out how to remove it. I was installing a red silicone STi throttle body hose to bling out the engine bay a bit so I took some photos and figured I'd write up an intercooler removal too. Tools needed - Flat head screw driver - 12mm socket, socket wrench + extension 1. Take a flat headed screwdriver and loosen the 2 hose clamps tying down the throttle body hose. 2. Remove the 2 12mm bolts connecting the stock bypass valve (or BOV) to the intercooler. 3. Remove the 12mm bolt holding the intercooler to the bracket on the driver's side (in yellow.) Also disconnect the hose connected to the black metal pipe (pointed to in blue.) 4. Remove the 12mm bolt holding the intercooler to the bracket on the passenger size (in yellow.) Also disconnect the 2 hoses connected to the black metal pipes (pointed to in blue.) 5. Loosen the hose clamp that connects the intercooler Y-Pipe to the turbo with a flat-head screwdriver. 6. Shake and pull on the intercooler a bit to loosen it and remove it from the turbo and throttle body. If you have a front strut bar you may have to remove it to get the intercooler out. I did to give me some more working room. 7. This is what you're left with. Now you can do whatever you need to do. I installed the STi red silicone throttle body hose. It just slipped on easily. Here was my end result: To re-install the intercooler: 1. To reconnect the intercooler to the turbo and the throttle body, position the Y-Hose next to the turbo and slip it on. Slide it back and forth until it's mostly on and then position the intercooler so you can slide it back over the throttle body hose. Push it on and it should slide back into place perfectly. 2. For the rest of reconnecting everything, reverse the steps above. TRM 23-AUG-2006: added to the How-To catalog sticky This ad is not endorsed by this member. Please register or login to hide this ad. Last edited by TRM : 08-23-2006 at 08:11 AM.

12-27-2007, 01:05 PM	#15
EarTears Amateur STI Driver Car: 06 Subaru WRX STi Fav Mod: Me in the driver seat Location: Florida Posts: 21 Join Date: Nov 2007 Trader Rating: (0)	Re: Intercooler removal / Throttle body hose install I can't view your pics either and I am not behind any web filtering. Could you possibly upload them to another server? It would be greatly appreciated! This ad is not endorsed by this member. Please register or login to hide this ad.

05-25-2006, 03:53 PM	#2
supermarkus Spec C Club Car: 08 STi, SSM Location: Edmonds Washington Posts: 1,441 Join Date: Dec 2005 Trader Rating: (0)	Nice write up, if you want to use a socket on those hose clamps I believe they are 8mm bolts.

05-25-2006, 10:24 PM	#3
JJ18Sniper Silver Member Car: 05 Subaru WRX STi Fav Mod: DB 20G, Diamond Black BBS RE's, S2K retrofit Location: NY Posts: 4,516 Join Date: Jul 2004 Trader Rating: (5)	Should sticky this for some folks.... Question for you as well: Have you had issues getting the turbo to intercooler red hose to stay on tightly? Mine seems to enjoy moving over time even when tightened down by the clamps.

05-26-2006, 01:03 AM	#4
JKonquer Spec C Club Car: AW 05 WRX STi Fav Mod: Recaro Racing Seats Location: CA-burbank and palm sprin Posts: 2,115 Join Date: Sep 2004 Trader Rating: (2)	what's the best way to connect y pipe hose to turbo? its very hard to get to and just wondering what's the easiest way to do it. mine is not in all the way, maybe 5mm space to the end.

05-26-2006, 05:44 AM	#5
jsh139 How YOU Doin? Car: 2006 Audi S4 Fav Mod: OMGHI2U! Location: Philly 'burbs Posts: 7,711 Join Date: Apr 2004 Trader Rating: (8)	I found that if you can't get the turbo to y-pipe hose back on the turbo outlet, it is alot easier to take off that hose from the y-pipe, and put it on the turbo-side first. Then, hold the hose as you slip the intercooler y-pipe onto it. You have more room for your hands if you do it this way. I have medium sized hands, and I couldn't fit them under the turbo to help guide the hose onto it. Just a thought.

05-26-2006, 06:01 AM	#6
Recyclebiz Amateur STI Driver Car: PSM '04 Sti Location: UT Posts: 17 Join Date: Apr 2005 Trader Rating: (0)	A quick word of advice - this will make it much easier to reinstall. Note the two bolts in the extreme lower left corner of picture #3. Remove them and take the bracket off as well. It'll give you a lot more "wiggle room" when you are trying to get the inlet hose back on to the turbo. Regards - Recyclebiz

05-26-2006, 08:35 AM	#9
lokutus1 Silver Member Car: 05 WRB WRX STi Fav Mod: FYI, I'm a dude Location: Burlington, MA Posts: 2,341 Join Date: Mar 2005 Trader Rating: (10)	nice write-up!

05-26-2006, 08:45 AM	#10
sebtarta Spec C Club Car: Waiting for the STI Fav Mod: Driving My Car Location: I Don't Know Posts: 1,661 Join Date: Sep 2005 Trader Rating: (7)	Nice write up!! Now when installing the IC best way is adding some oil just a dab (sp?) on the hose in order to help it slid in better to the turbo and throttle body.

11-28-2006, 05:06 PM	#12
sti_rules Junior STI Driver Car: 05 STi Fav Mod: I like it all! Location: Waynesboro, VA Posts: 143 Join Date: Sep 2006 Trader Rating: (1)	Yes, a dab of oil and they slip on like buttah!

12-01-2006, 06:41 AM	#13
DieselClown Amateur STI Driver Location: New York Posts: 48 Join Date: Sep 2004 Trader Rating: (0)	hey guys....are the pics loading up for you? they aren't for me!

12-01-2006, 09:30 AM	#14
kts262 HowTo Contributor Car: 2008 DGM (BBS+Navi) Fav Mod: stock FTL? Location: College Park, MD Posts: 2,087 Join Date: Jan 2005 Trader Rating: (7)	You must have some web filter software installed at work that doesn't like my image host. I'm moving to a new host soon. Check it out from home for now.