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Problems while installing an 06 intercooler

Posted: Wed Jul 23, 2008 6:45 am
by BlockerImp
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.

Posted: Wed Jul 23, 2008 3:12 pm
by dscoobydoo
read up on a few of us who have done it already. The answers are there.

Posted: Wed Jul 23, 2008 5:05 pm
by Dynamic Entry
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...

Posted: Wed Jul 23, 2008 10:45 pm
by dscoobydoo
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!

Posted: Thu Jul 24, 2008 5:45 am
by BlockerImp
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

Posted: Thu Jul 24, 2008 3:12 pm
by Legacy777
Are you using the VF11?

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

Posted: Thu Jul 24, 2008 3:52 pm
by dscoobydoo
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.

Posted: Thu Jul 24, 2008 4:51 pm
by BlockerImp
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?

Posted: Thu Jul 24, 2008 6:17 pm
by Dynamic Entry
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

Posted: Thu Jul 24, 2008 11:09 pm
by SubaruNation
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 ;)

Posted: Thu Jul 24, 2008 11:50 pm
by BlockerImp
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

Posted: Mon Jul 28, 2008 12:24 am
by BlockerImp
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??

Posted: Mon Jul 28, 2008 12:57 am
by know1
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

Posted: Mon Jul 28, 2008 4:32 am
by BlockerImp
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

Posted: Mon Jul 28, 2008 5:09 am
by know1
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 :P

Posted: Mon Jul 28, 2008 5:45 am
by BlockerImp
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

Posted: Mon Jul 28, 2008 10:56 pm
by SubaruNation
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.

Posted: Mon Jul 28, 2008 10:57 pm
by SubaruNation
i'll put up a close up here in a bit.

Posted: Mon Jul 28, 2008 11:52 pm
by BlockerImp
sounds good, thanks

Posted: Tue Jul 29, 2008 4:55 am
by SubaruNation
here we are:

the internetz are broken near my router.

cant upload to the gallery

Posted: Tue Jul 29, 2008 5:18 am
by BlockerImp
is there supposed to be a picture there? just use imageshack.us

Posted: Wed Jul 30, 2008 5:51 pm
by SubaruNation

Posted: Wed Jul 30, 2008 7:30 pm
by scuzzy
SubaruNation wrote:here team:

Image
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?

Posted: Wed Jul 30, 2008 8:37 pm
by SubaruNation
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

Posted: Thu Jul 31, 2008 12:33 am
by scuzzy
I was just being informative.

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