Step-by-step Installation of the Borgwarner Air to Water Intercooler on a Subaru Wrx

Installing the BorgWarner air to water intercooler on a Subaru WRX can significantly improve your vehicle’s performance. This guide provides a comprehensive, step-by-step process to ensure a successful installation.

Tools and Materials Needed

  • BorgWarner air to water intercooler kit
  • Socket set
  • Wrenches
  • Torque wrench
  • Drill with bits
  • Hoses and clamps
  • Coolant
  • Safety glasses
  • Rags

Preparation

Before starting the installation, ensure that your Subaru WRX is parked on a flat surface and the engine is cool. Gather all tools and materials listed above to streamline the process.

Step 1: Remove the Front Bumper

Begin by removing the front bumper to access the intercooler area. Follow these steps:

  • Remove the screws and clips securing the bumper.
  • Disconnect any electrical connectors for fog lights or sensors.
  • Carefully pull the bumper away from the vehicle.

Step 2: Remove the Stock Intercooler

Next, you will need to remove the stock intercooler. This involves:

  • Disconnecting the piping from the stock intercooler.
  • Removing the bolts that secure the intercooler to the vehicle.
  • Carefully lifting out the stock intercooler.

Step 3: Install the BorgWarner Intercooler

Now it’s time to install the BorgWarner air to water intercooler. Follow these steps:

  • Position the intercooler in place.
  • Secure it using the provided bolts.
  • Connect the inlet and outlet piping to the intercooler.

Step 4: Install the Water Lines

With the intercooler in place, you will need to install the water lines:

  • Attach the water lines to the intercooler.
  • Run the lines to the water reservoir or pump.
  • Secure the lines with clamps to prevent leaks.

Step 5: Refill the Coolant System

After installing the water lines, refill the coolant system:

  • Open the coolant reservoir cap.
  • Add the appropriate coolant mixture.
  • Check for any leaks in the system.

Step 6: Reinstall the Front Bumper

Once everything is secured and checked, reinstall the front bumper:

  • Align the bumper with the mounting points.
  • Reconnect any electrical connectors.
  • Secure the bumper with screws and clips.

Step 7: Final Checks

Before taking your Subaru WRX for a test drive, perform final checks:

  • Ensure all bolts and clamps are tight.
  • Check coolant levels once more.
  • Start the engine and look for any leaks.

Conclusion

Installing the BorgWarner air to water intercooler on your Subaru WRX can enhance your vehicle’s performance significantly. Following these steps will help ensure a smooth installation process. Enjoy your improved driving experience!