VF39 swap instructions w/pics

tankerWRX · 08-20-2006, 08:18 PM

First off I would like to thank MELD from the TXIC for helping me with the install and letting my car spill coolant all over his garage floor. We just finished a VF 39 install on my car so I thought I would take pics and post some instructions.

A lot of people seem to be getting hung up on the oil return lines and coolant lines. The coolant lines and banjo bolts from the TD04 ARE interchangeabe if your vf39 doesn't have them (mine didn't). The oil return line is not and must be modified in order to fit the vf39, (mine had it). Or get a new one from the dealer. I will explain in the pictures when I get to these items.

The #57 drill bit that COBB recommends you use to drill the restrictor pill if you are using their map is a pretty rare size. Most hardware stores won't carry it (I called a bunch), however you will have better luck finding it at a HOBBY/CRAFT shop. I paid $1 for it at a hobby store that has a lot of electric trains, remote control planes, cars etc...

If you want to replace the exhaust gaskets:
- Uppipe to turbo gasket's part number is #44022AA150.
- Turbo to downpipe gasket #44022AA180.

Ok on to the install. First remove the intercooler, pretty self explainatory there are 2 bolts that it mounts to, 2 on the BPV and the hoses. Done Deal. Next the heat shield. You should be somewhere around here:

Remove the downpipe:

Then remove the bolt for the oil inlet (top of the turbo), and start removing the coolant lines (2 lines coming off the side of the turbo 1 goes up 1 goes down). Be careful as you will lose coolant during this step be prepared to either catch it under the car or plug the line:

Then remove the 3 bolts that hold the turbo to the uppipe. Loosen from the intake remove vacuum lines and anything else attached to the turbo and you should be ready to take it off. The hose that the oil return line fits into is directly under the turbo and you should probably just lift straight out. Try to leave the hose where it is and lift the line out.

Now that the turbo is off you can start swapping out the parts you need from the td04. The coolant lines from the td04 will fit the vf39 however they are attached and too close together to fit directly on the vf39 see pic:

We broke the lines apart and bolted them on to the vf39 using the origional banjo bolts and washers:

Now for the oil return line my vf39 came with it so I did not need to replace or modify it but if your vf39 doesn't you will have to. Below is a side by side comparison between the td04 (left) and the vf39 (right):

On the T-shaped vacuum lines find the one with the restrictor pill in it (not hard to do there is a lump in the line) and drill out the pill with the #57 drill bit. You probably won't have to remove the pill from the line to do it. The pill is located in this line (picture from Cobb's website)

Once everything is ready to put back your engine bay should look something like this.

The oil outlet is kind of difficult just try to get the outlet pipe started into the hose before getting the air intake on.

Basically now you just put everything back together.

Replace your intercooler, top off the oil and coolant. Reflash your ECU or get your protune... and

infantsam · 08-21-2006, 07:20 AM

Good pics - I like the way you handled the oil fitting.

I am searching for a restrictor pill in the vacuum lines - it is not jumping out at me.

Can you remember which line it is in?

-the line out of the turbo outlet
-the line to the wastge actuator
-the line after the tee to the solenoid

Those drill bits are hard to find - I went to Grainger.

RP31 · 08-21-2006, 08:14 AM

It's in the line that comes from the turbo outlet.

See here: http://www.cobbtuning.com/wrx/access...20ProTUNER.pdf

equipment junkie · 08-21-2006, 10:19 AM

Very good write up - exactly how I did mine down to the oil line situation. Only two things to add:

1. I know this is obvious and should go without saying, but...Top off your coolant after everything has been bolted up.

2. I find that it is easier to re-install the turbo and intercooler hoses with just a little spary silicone for lubrication purposes. Also a cotter key removal tool (screwdriver with a pointed 90 degree bend in it - or "hook tool" as some people call it - works great for helping to "lip" the hose over the end of the tubo inlet etc.

Oh... and yeah go spank that bad boy after you fo your reflash - cause it hauls a$$!

Craig

infantsam · 08-21-2006, 11:03 AM

Hunting and hunting

No pill for me -

I get boost spikes in high load - 3-4th gear uphill fro example

Hmm - should I maek a pill?? - If so where do I put it?

equipment junkie · 08-21-2006, 11:12 AM

If you look at the picture shown a couple of posts above (from the cobb ap info) - you'll see where the pill is supposed to be. If for dome reason there is no pill inside the particular vacume line as indicated in the photo - you should be able to purchase one from your loca Subaru dealership.
Drill it out as described, place it into the vacume line - lube it with silicone spray (or even some light oil) - push it into the vacume line 1/2 " to 3/4". Obviously, you want to make sure that the
drilled hole in the brass pill is aligned with the vacume tube to allow air to pass throught it (I know it sounds pretty obvious - but I've seen simpler things screwed up!)

infantsam · 08-21-2006, 02:01 PM

Quote:

Originally Posted by equipment junkie

If you look at the picture shown a couple of posts above (from the cobb ap info) - you'll see where the pill is supposed to be. If for dome reason there is no pill inside the particular vacume line as indicated in the photo - you should be able to purchase one from your loca Subaru dealership.
Drill it out as described, place it into the vacume line - lube it with silicone spray (or even some light oil) - push it into the vacume line 1/2 " to 3/4". Obviously, you want to make sure that the
drilled hole in the brass pill is aligned with the vacume tube to allow air to pass throught it (I know it sounds pretty obvious - but I've seen simpler things screwed up!)

I hear ya - thanks - preceeding with more care

El Capitan · 02-25-2007, 10:30 AM

Quote:

Originally Posted by equipment junkie

If you look at the picture shown a couple of posts above (from the cobb ap info) - you'll see where the pill is supposed to be. If for dome reason there is no pill inside the particular vacume line as indicated in the photo - you should be able to purchase one from your loca Subaru dealership.
Drill it out as described, place it into the vacume line - lube it with silicone spray (or even some light oil) - push it into the vacume line 1/2 " to 3/4". Obviously, you want to make sure that the
drilled hole in the brass pill is aligned with the vacume tube to allow air to pass throught it (I know it sounds pretty obvious - but I've seen simpler things screwed up!)

While I worked at Trollhattan Motors (a SAAB & Volvo place) a few years back, we had learned from the Bosch School in California that silicone spray should not be used anywhere it could be sucked into the engine. In small amounts it is supposed to casue the Lambda to prematurly fail or give bad readings and in large amounts will casue it to go haywire almost right away.

Are there and chemists out there who can confirm? Regular O2 sensors are expensive enough, I'd hate for some one to prematurly ruin a wideband.

WRX_JUNKi · 08-21-2006, 01:50 PM

What year was the STI top mount from? Was it a direct bolt on?

SubasaurusWrex · 08-21-2006, 02:03 PM

nice write up but it isn't exactly rocket-surgery.

Tomnel · 08-21-2006, 02:44 PM

Thanks! theres nothing like seeing pics and a step by step before tackling this for the first time.

coil222 · 10-01-2006, 08:48 PM

Quote:

Originally Posted by Tomnel

Thanks! theres nothing like seeing pics and a step by step before tackling this for the first time.

+12345

Subscribing this for when I pull my turbo for WG portage!

ghibli99 · 08-21-2006, 05:10 PM

Thanks for the nice write-up, pictures, and for the tips from others in this thread. This is a popular first swap, so it's good to get multiple perspectives from people who have done it.

-Mike

tankerWRX · 08-21-2006, 08:28 PM

Added a pic to show where the restrictor pill is to the first post. Pic from Cobb's website:

infantsam · 08-21-2006, 09:40 PM

Today was a bad post day for me - I got yelled at all over. Thanks - that's from the MAP notes I was supposed to read eh??

I did find it - now I just gotta drill it out - I have 2 bits coming from Grainger tomorrow - If I don't bust them I can offer them to anyone who wants to save the time looking around for them.

ILSMKU2 · 08-22-2006, 12:08 AM

+1 for swapping turbos with flip flops on!

06BlackSTIwith550WHP · 03-22-2007, 03:20 PM

Quote:

Originally Posted by djennison

+1 for swapping turbos with flip flops on!

thats funny, when i work on my car in my garage I work barefoot, whenever someone walks the first thing I hear is why the hell are you barefoot?

E6V6I6L · 03-22-2007, 09:03 PM

I spoke with cobb before I did mine and they told me first hand that an 04/05 sti restrictor pill is the right size. I decided to drill mine cuz the bit was only
0.70 but if a local dealer has one might as well get it.

06rexwagon · 03-22-2007, 09:39 PM

Quote:

Originally Posted by E6V6I6L

I spoke with cobb before I did mine and they told me first hand that an 04/05 sti restrictor pill is the right size. I decided to drill mine cuz the bit was only
0.70 but if a local dealer has one might as well get it.

Good to know. Mine came with all the vacuum lines and the stock sti boost solenoid.

bnb_lee · 09-21-2007, 01:02 AM

Quote:

Originally Posted by djennison

+1 for swapping turbos with flip flops on!

flippies are crazy

cwepruk · 08-22-2006, 10:03 AM

I got a part number for a new vacuum line assembly from someone at Subaruforester.org (part person) who said this was the correct vacuum hose to use for a VF39 swap. Can anyone verify this one?

Vacuum Hoses - 14447AA090
Boost Restrictor Pill - Included w/ Hose Assembly

meld · 08-22-2006, 11:17 AM

HAHAH, LOL, that is me in the flip flops holding the turbo.....

06BLUEREX · 08-22-2006, 12:04 PM

very good detailed instructions/info and pictures.

have a blast with your car!!

ILSMKU2 · 08-22-2006, 12:08 PM

Quote:

Originally Posted by Meld

HAHAH, LOL, that is me in the flip flops holding the turbo.....

Awesome! I do it all the time too.

-DJ

subieworx · 08-22-2006, 12:38 PM

Me too. I am always working i flip flops.

08-20-2006, 08:18 PM	#1
tankerWRX Scooby Newbie Member#: 102053 Join Date: Dec 2005 Chapter/Region: TXIC Location: Baghdad, Iraq Vehicle: 2007 LGT (Sold)	VF39 install instructions w/pics '06 WRX First off I would like to thank MELD from the TXIC for helping me with the install and letting my car spill coolant all over his garage floor. We just finished a VF 39 install on my car so I thought I would take pics and post some instructions. A lot of people seem to be getting hung up on the oil return lines and coolant lines. The coolant lines and banjo bolts from the TD04 ARE interchangeabe if your vf39 doesn't have them (mine didn't). The oil return line is not and must be modified in order to fit the vf39, (mine had it). Or get a new one from the dealer. I will explain in the pictures when I get to these items. The #57 drill bit that COBB recommends you use to drill the restrictor pill if you are using their map is a pretty rare size. Most hardware stores won't carry it (I called a bunch), however you will have better luck finding it at a HOBBY/CRAFT shop. I paid $1 for it at a hobby store that has a lot of electric trains, remote control planes, cars etc... If you want to replace the exhaust gaskets: - Uppipe to turbo gasket's part number is #44022AA150. - Turbo to downpipe gasket #44022AA180. Ok on to the install. First remove the intercooler, pretty self explainatory there are 2 bolts that it mounts to, 2 on the BPV and the hoses. Done Deal. Next the heat shield. You should be somewhere around here: Remove the downpipe: Then remove the bolt for the oil inlet (top of the turbo), and start removing the coolant lines (2 lines coming off the side of the turbo 1 goes up 1 goes down). Be careful as you will lose coolant during this step be prepared to either catch it under the car or plug the line: Then remove the 3 bolts that hold the turbo to the uppipe. Loosen from the intake remove vacuum lines and anything else attached to the turbo and you should be ready to take it off. The hose that the oil return line fits into is directly under the turbo and you should probably just lift straight out. Try to leave the hose where it is and lift the line out. Now that the turbo is off you can start swapping out the parts you need from the td04. The coolant lines from the td04 will fit the vf39 however they are attached and too close together to fit directly on the vf39 see pic: We broke the lines apart and bolted them on to the vf39 using the origional banjo bolts and washers: Now for the oil return line my vf39 came with it so I did not need to replace or modify it but if your vf39 doesn't you will have to. Below is a side by side comparison between the td04 (left) and the vf39 (right): On the T-shaped vacuum lines find the one with the restrictor pill in it (not hard to do there is a lump in the line) and drill out the pill with the #57 drill bit. You probably won't have to remove the pill from the line to do it. The pill is located in this line (picture from Cobb's website) Once everything is ready to put back your engine bay should look something like this. The oil outlet is kind of difficult just try to get the outlet pipe started into the hose before getting the air intake on. Basically now you just put everything back together. Replace your intercooler, top off the oil and coolant. Reflash your ECU or get your protune... and Last edited by tankerWRX; 08-21-2006 at 08:33 PM.

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08-21-2006, 07:20 AM	#2
infantsam Scooby Specialist Member#: 51280 Join Date: Dec 2003 Chapter/Region: South East Vehicle: 06 VF-39 is good	Good pics - I like the way you handled the oil fitting. I am searching for a restrictor pill in the vacuum lines - it is not jumping out at me. Can you remember which line it is in? -the line out of the turbo outlet -the line to the wastge actuator -the line after the tee to the solenoid Those drill bits are hard to find - I went to Grainger.

08-21-2006, 08:14 AM	#3
RP31 Scooby Specialist Member#: 123574 Join Date: Aug 2006 Chapter/Region: MWSOC Location: Hanover Park, IL Vehicle: 2005 2.6L 9:1 425WHP CGM STi	It's in the line that comes from the turbo outlet. See here: http://www.cobbtuning.com/wrx/access...20ProTUNER.pdf

08-21-2006, 10:19 AM	#4
equipment junkie Scooby Specialist Member#: 97607 Join Date: Oct 2005 Chapter/Region: TXIC Location: Houston, Texas Vehicle: 2006 wrx wrx blue	Very good write up - exactly how I did mine down to the oil line situation. Only two things to add: 1. I know this is obvious and should go without saying, but...Top off your coolant after everything has been bolted up. 2. I find that it is easier to re-install the turbo and intercooler hoses with just a little spary silicone for lubrication purposes. Also a cotter key removal tool (screwdriver with a pointed 90 degree bend in it - or "hook tool" as some people call it - works great for helping to "lip" the hose over the end of the tubo inlet etc. Oh... and yeah go spank that bad boy after you fo your reflash - cause it hauls a$$! Craig

08-21-2006, 11:03 AM	#5
infantsam Scooby Specialist Member#: 51280 Join Date: Dec 2003 Chapter/Region: South East Vehicle: 06 VF-39 is good	Hunting and hunting No pill for me - I get boost spikes in high load - 3-4th gear uphill fro example Hmm - should I maek a pill?? - If so where do I put it?

08-21-2006, 11:12 AM	#6
equipment junkie Scooby Specialist Member#: 97607 Join Date: Oct 2005 Chapter/Region: TXIC Location: Houston, Texas Vehicle: 2006 wrx wrx blue	If you look at the picture shown a couple of posts above (from the cobb ap info) - you'll see where the pill is supposed to be. If for dome reason there is no pill inside the particular vacume line as indicated in the photo - you should be able to purchase one from your loca Subaru dealership. Drill it out as described, place it into the vacume line - lube it with silicone spray (or even some light oil) - push it into the vacume line 1/2 " to 3/4". Obviously, you want to make sure that the drilled hole in the brass pill is aligned with the vacume tube to allow air to pass throught it (I know it sounds pretty obvious - but I've seen simpler things screwed up!)

08-21-2006, 01:50 PM	#9
WRX_JUNKi Scooby Specialist Member#: 100695 Join Date: Nov 2005 Chapter/Region: Tri-State Location: NYC Vehicle: 2006 WRX Limited WRB	What year was the STI top mount from? Was it a direct bolt on?

08-21-2006, 02:03 PM	#10
SubasaurusWrex Scooby Specialist Member#: 70285 Join Date: Sep 2004 Location: Schaumburg, IL Vehicle: 2011 JCW Mini Midnight Black/Red roof	nice write up but it isn't exactly rocket-surgery.

08-21-2006, 02:44 PM	#11
Tomnel Scooby Specialist Member#: 12625 Join Date: Nov 2001 Chapter/Region: SCIC Location: San Fernando Valley CA Vehicle: MY02 WRX Impreza Silver	Thanks! theres nothing like seeing pics and a step by step before tackling this for the first time.

08-21-2006, 05:10 PM	#13
ghibli99 Scooby Specialist Member#: 90761 Join Date: Jul 2005 Chapter/Region: SWIC Location: Phoenix Vehicle: 2003 S2000 Save the Manuals!	Thanks for the nice write-up, pictures, and for the tips from others in this thread. This is a popular first swap, so it's good to get multiple perspectives from people who have done it. -Mike

08-21-2006, 08:28 PM	#14
tankerWRX Scooby Newbie Member#: 102053 Join Date: Dec 2005 Chapter/Region: TXIC Location: Baghdad, Iraq Vehicle: 2007 LGT (Sold)	Added a pic to show where the restrictor pill is to the first post. Pic from Cobb's website:

08-21-2006, 09:40 PM	#15
infantsam Scooby Specialist Member#: 51280 Join Date: Dec 2003 Chapter/Region: South East Vehicle: 06 VF-39 is good	Today was a bad post day for me - I got yelled at all over. Thanks - that's from the MAP notes I was supposed to read eh?? I did find it - now I just gotta drill it out - I have 2 bits coming from Grainger tomorrow - If I don't bust them I can offer them to anyone who wants to save the time looking around for them.

08-22-2006, 12:08 AM	#16
ILSMKU2 Scooby Specialist Member#: 77908 Join Date: Dec 2004 Chapter/Region: SCIC Location: OC Vehicle: 2011 E92 ///M3 RIP 11, 09, 06, 03 STI's	+1 for swapping turbos with flip flops on!

03-22-2007, 09:03 PM	#18
E6V6I6L Scooby Specialist Member#: 123710 Join Date: Aug 2006 Chapter/Region: MWSOC Location: On the toilet	I spoke with cobb before I did mine and they told me first hand that an 04/05 sti restrictor pill is the right size. I decided to drill mine cuz the bit was only 0.70 but if a local dealer has one might as well get it.

08-22-2006, 10:03 AM	#21
cwepruk Scooby Newbie Member#: 121757 Join Date: Aug 2006 Location: Edmonton, Alberta Vehicle: 2005 Subaru Forester White	I got a part number for a new vacuum line assembly from someone at Subaruforester.org (part person) who said this was the correct vacuum hose to use for a VF39 swap. Can anyone verify this one? Vacuum Hoses - 14447AA090 Boost Restrictor Pill - Included w/ Hose Assembly

08-22-2006, 11:17 AM	#22
meld Scooby Specialist Member#: 91217 Join Date: Jul 2005 Chapter/Region: TXIC Location: aw Vehicle: 06 Evo IX / 04' R1 Tarmac Black	HAHAH, LOL, that is me in the flip flops holding the turbo.....

08-22-2006, 12:04 PM	#23
06BLUEREX Scooby Newbie Member#: 120000 Join Date: Jul 2006	very good detailed instructions/info and pictures. have a blast with your car!!

08-22-2006, 12:38 PM	#25
subieworx Scooby Guru Member#: 47769 Join Date: Nov 2003 Chapter/Region: MWSOC	Me too. I am always working i flip flops.