APS intercooler install 04-07 STi Tools required:-7mm, 8mm, 10mm, 12mm sockets
-12mm wrench
-phillips screwdriver #2
-common screwdriver
-needle nose pliers
-Xacto blade
-ruler
-scrubby pad (scotch brite)
-Permatex black gasket maker
-vaseline
Step 1: Removal of TMIC-Remove all bolts marked in red, make sure you note the positions of where they are installed.
-Loosen the clamps on the turbo outlet, and the throttle body coupling.
-Remove the vacuum lines that directly attach to the TMIC piping.
Once you’ve got all those complete, then you can lift the stock TMIC out of the engine bay.
Step 2: Removal of TMIC support braces-Remove the two bolts that attach the driver side top mount bracket to the intake manifold, keep the bracket safe, because it will be re-installed later.
-Remove the two bolts which secure the passenger side bracket to the back side of the block, which will be replaced by the one supplied by the kit.
Step 3 : Stripping old TMIC (keep all parts, they will be re-used)-Remove the three bolts which attach the vacuum crosspipe to the face of the intercooler.
-Remove the 4 bolts which attach the inlet charge pipe to the intercooler rear body.
-Remove both bushings from both side mounting points. To remove them, push the sleeve out of the rubber bushing with your thumb, then remove the rubber bushing from the mount on the side of the intercooler.
-Remove TMIC to Throttle body coupler.
Step 4 : Prepping charge pipes-Remove old gaskets from the charge pipes with the Xacto blade. TAKE YOUR TIME, and be careful not to mar or gouge the aluminum surface of the charge pipes. The old gaskets are glued into place, so they will not come off easily. Once the actual gasket has been removed, use a scotch brite pad to get rid of any glue residue left over.
-After both surfaces are good and clean, smear a VERY LIGHT coat of permatex gasket maker on the new charge pipe gaskets supplied in the kit, make sure to completely cover both sides and all parts of the gasket.
-Place gasket on charge pipe
Step 5 : Prepping new TMIC-Install charge pipe with 4 bolts removed in step 3.
NOTE : install clamp for elbow at the 6 o’clock position on charge pipe.
Torque for nuts is 12 ft/lbs-Install vacuum crosspipe removed in step 3 with supplied hardware from kit. MAKE sure you install the spacers behind the lines.
Torque for nuts is 5 ft/lbs-Install TMIC to throttle body coupler removed in step 3, do not tighten clamps at this time
Step 6 : Installation of Passenger side TMIC support-Install the passenger side TMIC support supplied in kit, using hardware removed in step 2. Center the holes as best you can, and tighten the bolts.
Torque for bolts is 12 ft/lbsStep 7 : Installation of TMIC-Slide new TMIC into place, making sure not to damage the couplings for the turbo outlet or the throttle body.
HINT lightly coat insides of both couplings with vaceline, it will make the job MUCH easier
-Once TMIC is sitting in place, install driver side TMIC support brace. Tighten both bolts into intake manifold removed in step 2.
Torque for bolts is 12 ft/lbs-Install and tighten both side support bolts removed in step 1 into both support braces.
Torque for bolts is 12 ft/lbs-Tighten turbo outlet clamp and TMIC to Throttle body clamps (3 in total)
Torque for clamps is 3 ft/lbs-Install all vacuum lines that attach to TMIC crosspipe. (3 in total)
-Install bypass valve o-ring supplied in kit, and then install bypass valve to front of TMIC.
Torque for nuts is 12 ft/lbsStep 8 : Removal of Hood Splitter-disconnect the water sprayer line attached to the hood diffuser
-Remove 7 bolts holding the splitter to the hood. Marked in red
-Remove plastic screw and clip from the splitter. Upper center, also marked in red
-Carefully remove splitter from hood, by disengaging the two tabs on the bottom edge.
Step 9 : Removal of Hood Scoop-Remove 6 nuts marked in red
-Using needle nose pliers, pinch the plastic tabs marked in yellow to release them from the hood
BE CAREFUL : the hood scoop will fall if you don’t support it
Step 10 : Prepping splitter-Using needle nose pliers, pinch the backsides of the plastic tabs holding the rubber sealing ring on the splitter.
-Bend the forward edge of the opening in the splitter aft (marked in red), so it aligns with the rest of the metal in the opening of the splitter. It should look pretty close to what is pictured. It does
not have to move very far
Step 11 : Prepping sealing strip-cut off the sealing ring approximately 15mm’s down all the way around (marked in yellow).
-re-install the sealing ring to the hood splitter, using all clips removed in step 10
-temporarily re-install hood splitter to hood.
Step 12 : Checking seal for any interference-CAREFULLY lower the hood, working slowly, moving inch by inch to make sure nothing comes into contact with each other. Once you can lower the hood until it rests on the latch without contacting anything, then proceed to close the hood normally. Again, check how the seal rests on the TMIC. Make sure it doesn’t bunch up, or come into contact with the fins on the TMIC. Also, make sure that the forward edge you bent in step 10 doesn’t contact the vacuum crosspipes across the front of the TMIC. If it does, bend the tab a little more in the direction needed.
-Once all is confirmed good with fit, then remove the splitter, re-install the hood scoop, and then re-install the splitter.