STi intercooler installed on an 06 WRX Wagon plus more

Peleg · 10-14-2006, 08:24 PM

Today I helped my sister's b/f install some goodies on his stock 06 WRX Wagon.

He found a used STi intercooler in good condition, bought a used OEM boost gauge and his Cobb AP has arrived, so we had a fun day installing everything.

Boost gauge install

We first started with the used boost gauge, which didn't come with the T splitter that we needed to hook up to the BPV. A quick trip the Monmument Car parts and we found a splitter that later fitter perfectly.

We followed the OEM instructions from Subaru and installed the gauge, working from the interior to the engine bay.

We drilled holes into the upper steering cover and mounted the gauge, but we mounted it too close to the turn signal arm. We took it off, looked at my STi setup and re drilled more holes. This time is was dead on.

We routed the electrical connection to the back of the stereo and plugged in the harness.

We then routed the vaccum line through the firewall hole to the engine bay.

STi intercooler

Before you start mounting an STi intercooler on an 06 WRX, you'll need the following parts ahead of time to save you 2 hours, and 4 trips, one to the dealer!

1. An STi BPV gasket.
2. An aftermarket vaccum piece that goes from the turbo's compressor to the new IC. The stock STi piece was too short.
3. One size bigger clamp than the one that came with the STi intercooler. (this one will be used to connect the new vaccum piece to the compressor.

We first cleaned the IC and polished it. You can use a water/citrus based engine degreaser to clean the outside from dirt/grime.

We than replaced the black metal piping from the STi with the stock one, and the stock throttlebody rubber piece.

The intercooler is now ready to be dropped in which was quite a PITA. We had to take it out 3 times in order to trim the compressor vaccum piece for perfect fitment, but at the end it worked.

We hooked up all the remaining lines.

We then hooked up the BPV with the new gasket to the IC and connected the boost gauge vaccum hose. We used zip ties to fasten the vaccum line from the boost gauge to AC hose.

Started the car and everything looked and sounded great. No boost leaks, no CEL's.

The car did feel a bit more powerful after a quick freeway run.

We got back and installed the AP which was a breeze.

This wagon is now a lil monster, and you should have seen the smile on Rob's face - priceless.

***Insane06STi*** · 10-14-2006, 08:26 PM

Nice job!

Peleg · 11-12-2006, 06:32 PM

After a few weeks, Rob started to hear a certain noise upon take off.

It was only during 1st gear take off at a certain RPM.

Solution: the back of the STi intercooler was rubbing against a metal pipe that goes near the A/C condensner pipe.

We used some rubber to insulate it, problem solved.

Knight · 12-05-2006, 03:20 PM

How long did the install take?

scubadiver424 · 12-05-2006, 03:23 PM

looks good! Nice!

Schell · 12-08-2006, 09:55 AM

I think it took about 2-3 hours for the I/C, but that doesn't include the time we spent driving to the dealership. When we took it off to troubleshoot the rattle, the take off/re-install was about 5 minutes. It's just a PITA to get both hoses on simultaneously, if you're going to take it off yourself I highly suggest you have a buddy around to help you put it back on

.

10-14-2006, 08:24 PM	#1
Peleg STI Guru Car: 04 Subaru WRX STi Fav Mod: Whooshing sounds Location: NorCal Posts: 5,662 Join Date: Nov 2003 Trader Rating: (11)	STi intercooler installed on an 06 WRX Wagon plus more Today I helped my sister's b/f install some goodies on his stock 06 WRX Wagon. He found a used STi intercooler in good condition, bought a used OEM boost gauge and his Cobb AP has arrived, so we had a fun day installing everything. Boost gauge install We first started with the used boost gauge, which didn't come with the T splitter that we needed to hook up to the BPV. A quick trip the Monmument Car parts and we found a splitter that later fitter perfectly. We followed the OEM instructions from Subaru and installed the gauge, working from the interior to the engine bay. We drilled holes into the upper steering cover and mounted the gauge, but we mounted it too close to the turn signal arm. We took it off, looked at my STi setup and re drilled more holes. This time is was dead on. We routed the electrical connection to the back of the stereo and plugged in the harness. We then routed the vaccum line through the firewall hole to the engine bay. STi intercooler Before you start mounting an STi intercooler on an 06 WRX, you'll need the following parts ahead of time to save you 2 hours, and 4 trips, one to the dealer! 1. An STi BPV gasket. 2. An aftermarket vaccum piece that goes from the turbo's compressor to the new IC. The stock STi piece was too short. 3. One size bigger clamp than the one that came with the STi intercooler. (this one will be used to connect the new vaccum piece to the compressor. We first cleaned the IC and polished it. You can use a water/citrus based engine degreaser to clean the outside from dirt/grime. We than replaced the black metal piping from the STi with the stock one, and the stock throttlebody rubber piece. The intercooler is now ready to be dropped in which was quite a PITA. We had to take it out 3 times in order to trim the compressor vaccum piece for perfect fitment, but at the end it worked. We hooked up all the remaining lines. We then hooked up the BPV with the new gasket to the IC and connected the boost gauge vaccum hose. We used zip ties to fasten the vaccum line from the boost gauge to AC hose. Started the car and everything looked and sounded great. No boost leaks, no CEL's. The car did feel a bit more powerful after a quick freeway run. We got back and installed the AP which was a breeze. This wagon is now a lil monster, and you should have seen the smile on Rob's face - priceless. This ad is not endorsed by this member. Please register or login to hide this ad. Last edited by Peleg : 10-14-2006 at 08:27 PM.

11-12-2006, 06:32 PM	#3
Peleg STI Guru Car: 04 Subaru WRX STi Fav Mod: Whooshing sounds Location: NorCal Posts: 5,662 Join Date: Nov 2003 Trader Rating: (11)	Quick update After a few weeks, Rob started to hear a certain noise upon take off. It was only during 1st gear take off at a certain RPM. Solution: the back of the STi intercooler was rubbing against a metal pipe that goes near the A/C condensner pipe. We used some rubber to insulate it, problem solved.

12-08-2006, 09:55 AM	#6
Schell Silver Member Car: 2006 WRX Wagon 6 Spd Fav Mod: Having my car back after 2 months!!! Location: Bay Area Posts: 546 Join Date: Oct 2006 Trader Rating: (4)	I think it took about 2-3 hours for the I/C, but that doesn't include the time we spent driving to the dealership. When we took it off to troubleshoot the rattle, the take off/re-install was about 5 minutes. It's just a PITA to get both hoses on simultaneously, if you're going to take it off yourself I highly suggest you have a buddy around to help you put it back on . This ad is not endorsed by this member. Please register or login to hide this ad.

10-14-2006, 08:26 PM	#2
*Insane06STi* Nanned ® Location: Where the left lane is th Posts: 17,349 Join Date: Oct 2005 Trader Rating: (9)	Nice job!

12-05-2006, 03:20 PM	#4
Knight Junior STI Driver Car: 06 STI - OBP Fav Mod: Borla Catback!! Location: Mountain View, CA Posts: 191 Join Date: Jun 2006 Trader Rating: (0)	How long did the install take?

12-05-2006, 03:23 PM	#5
scubadiver424 S204 Racer Car: 06 WRB GOLD STI Fav Mod: NRA Sticker Location: US of A Posts: 3,626 Join Date: Mar 2006 Trader Rating: (8)	looks good! Nice!