Problems while installing an 06 intercooler

BlockerImp · Post by **BlockerImp** » Wed Jul 23, 2008 6:45 am

Ok, so i got all the easy stuff taken care off. Relocated my Coolant tank A'la SubaruNation, Tucked A/C and wire loom under the pitch stop, remounted the ignitor chip.

Now for the problems, the clutch master resivoir. What the hell should i do with it? I dont have the offset one, and im kinda nervous about cutting it. From where i have it, it shouldnt be MUCH of a problem just leaving it alone, but its one of the thing thats holding my intercooler too high.

Also, how the hell am i supposed to get the intercooler to match up with the Turbo Outlet? i mean, i know imma need some hoses, but for the stock y pipe, do i need to cut it? what sort of combination of hoses do i need to make it fit?? nothing ive read explained it clearly enough. Seems as though i might need 3 pieces of hosing, 1 in particular being a 45* one.

After i get this all figured out, ill post my build with details.

dscoobydoo · Post by **dscoobydoo** » Wed Jul 23, 2008 3:12 pm

read up on a few of us who have done it already. The answers are there.

Dynamic Entry · Post by **Dynamic Entry** » Wed Jul 23, 2008 5:05 pm

don't be afraid to cut the reservoir. about an inch off the bottom is what i did.

i got nothing when it comes to plumbing to the VF11. I was defeated in that regard also...

dscoobydoo · Post by **dscoobydoo** » Wed Jul 23, 2008 10:45 pm

Go to a junkyard, and find a MC that has the right side offset. I did. It was cheap and it works great WITHOUT HAVING TO CUT THE TOP!

BlockerImp · Post by **BlockerImp** » Thu Jul 24, 2008 5:45 am

ok, Cut the MC, intercooler sits more perpendicular now. But i still cant get the damned turbo outlet to mate up to the intercooler.

I have done my research, but i have NO idea how the hell anyone managed to ever get them to match up. I bought the 8338 napa hose, i have silicone elbows, piping, and everything.

The napa hose bends, the silicone elbow doesnt want to match up.

I need some sort of definative of how people managed to get it to work. Like where on the stock Y-Pipe did you cut, how do you have it connected to whatever degree elbow, and what do you have connected to the turbo outlet.

Please dont tell me to look, cause i have. I have tried 3 different ways as shown, but without an accurate description this is becoming very frustrating

Post by **Legacy777** » Thu Jul 24, 2008 3:12 pm

Are you using the VF11?

It's just going to be a pain.....these things don't go together easily.

dscoobydoo · Post by **dscoobydoo** » Thu Jul 24, 2008 3:52 pm

Sorry, I should have clarified WHICH turbo you are using.

The VF-11 is almost impossible, unless you have the time to visualize what bends and what size hoses you need. It is purely custom on each car at that point. But the outlet angle almost makes it impossible to use the 06 on the VF-11. At that point, I would source a cheap used TD04 and change it out.

I used a TD05, so it was easy in comparison.

BlockerImp · Post by **BlockerImp** » Thu Jul 24, 2008 4:51 pm

ok, well i do have a td04 laying around. Thing is, i have never installed a turbo nor do i have any idea how to go about it. I do have my Chiltons service manual, and could probably figure it out. The main problem if i recall is just getting a 90* for the inlet? if thats the case then we will see.

As for the td05, what makes it so easy? i know it has the 90* inlet still, but whats different about the outlet?

Dynamic Entry · Post by **Dynamic Entry** » Thu Jul 24, 2008 6:17 pm

the TD05 and TD04 (and I think all the turbos that came after the VF11) have an outlet that sits parallel to the ground instead of at an angle

wrx intercoolers were built and plumbed with this geometry in mind so trying to get the plumbing to fit on a VF11 is a challenging custom job where as plumbing to a WRX turbo is more like bolt on

SubaruNation · Post by **SubaruNation** » Thu Jul 24, 2008 11:09 pm

maybe i should do a HOW-TO for this specifically?
i know i'm not the only one that has doe this to the vf11...

and you don't have to cut the MC or whatever, i KNOW i didn't.

send me a pic of your problem and i will help you out for sure

BlockerImp · Post by **BlockerImp** » Thu Jul 24, 2008 11:50 pm

i sent you a PM, I could really use some help on this though. Dont have a picture yet cause my GF took my digicam. But ill see what i can do

BlockerImp · Post by **BlockerImp** » Mon Jul 28, 2008 12:24 am

ok,new problem. The diameter of my bpv flange is 1.25" but the inlet on the BPV itself is .75". What did you do to get around that??

know1 · Post by **know1** » Mon Jul 28, 2008 12:57 am

get a reducer, then buy .75 rad hose. Cut your 1.25 hose, insert reducer, attach reducer to .75 hose and run hose to bpv

BlockerImp · Post by **BlockerImp** » Mon Jul 28, 2008 4:32 am

this reducer, is it just like a fitting i can get somewhere? cause when i was looking at lowes/HD there only seemed to be like .75 to .5" reducers

know1 · Post by **know1** » Mon Jul 28, 2008 5:09 am

yeah basically, I have no idea where you could find one. What materials were you looking at? Plastic stuff or metal stuff? The plumbing section might have more options for you. If not, you are going to have to scour the web for something or maybe try and find somewhere that deals with REALLY small exhausts who would have that

BlockerImp · Post by **BlockerImp** » Mon Jul 28, 2008 5:45 am

hmm, ill have to see. My turbo inlet pipe broke on the outlet that goes to the BPV, so until i get my silicone 90*, i gotta wait, but i figure i can find out this info first

SubaruNation · Post by **SubaruNation** » Mon Jul 28, 2008 10:56 pm

i used a radiator hose and i had a Plastic piece that made an airtight seal around it.

here is a pic:

i ran the radiator hose from the weird rubber deal to the BPV.. then to the intercooler.

SubaruNation · Post by **SubaruNation** » Mon Jul 28, 2008 10:57 pm

i'll put up a close up here in a bit.

BlockerImp · Post by **BlockerImp** » Mon Jul 28, 2008 11:52 pm

sounds good, thanks

SubaruNation · Post by **SubaruNation** » Tue Jul 29, 2008 4:55 am

here we are:

the internetz are broken near my router.

cant upload to the gallery

BlockerImp · Post by **BlockerImp** » Tue Jul 29, 2008 5:18 am

is there supposed to be a picture there? just use imageshack.us

SubaruNation · Post by **SubaruNation** » Wed Jul 30, 2008 5:51 pm

scuzzy · Post by **scuzzy** » Wed Jul 30, 2008 7:30 pm

SubaruNation wrote:here team:

you can see the plastic pipe (well it used to be rubber i guess lol) that fits over either side of the BPV and then i used rad hose over the top of that.

anything will work really as long as you make a good seal

Didn't notice the arrow on the bypass valve, did you?

SubaruNation · Post by **SubaruNation** » Wed Jul 30, 2008 8:37 pm

guess not, just fixed that.

you get the basic idea of what i did however to create the seal since that was the morel of this story. not the snide comments by scuzzy

scuzzy · Post by **scuzzy** » Thu Jul 31, 2008 12:33 am

I was just being informative.

Don't try so hard to read between the lines.

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Problems while installing an 06 intercooler

Problems while installing an 06 intercooler