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Old 08-20-2006, 08:18 PM   #1
tankerWRX
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Default 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
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Last edited by tankerWRX; 08-21-2006 at 08:33 PM.
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Old 08-21-2006, 07:20 AM   #2
infantsam
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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.
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Old 08-21-2006, 08:14 AM   #3
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It's in the line that comes from the turbo outlet.

See here: http://www.cobbtuning.com/wrx/access...20ProTUNER.pdf
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Old 08-21-2006, 10:19 AM   #4
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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
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Old 08-21-2006, 11:03 AM   #5
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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?
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Old 08-21-2006, 11:12 AM   #6
equipment junkie
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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!)
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Old 08-21-2006, 01:50 PM   #7
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What year was the STI top mount from? Was it a direct bolt on?
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Old 08-21-2006, 02:01 PM   #8
infantsam
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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

Last edited by infantsam; 08-21-2006 at 02:14 PM.
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Old 08-21-2006, 02:03 PM   #9
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nice write up but it isn't exactly rocket-surgery.
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Old 08-21-2006, 02:44 PM   #10
Tomnel
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Thanks! theres nothing like seeing pics and a step by step before tackling this for the first time.
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Old 08-21-2006, 05:10 PM   #11
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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
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Old 08-21-2006, 08:28 PM   #12
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Added a pic to show where the restrictor pill is to the first post. Pic from Cobb's website:

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Old 08-21-2006, 09:40 PM   #13
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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.
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Old 08-22-2006, 12:08 AM   #14
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+1 for swapping turbos with flip flops on!

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Old 08-22-2006, 10:03 AM   #15
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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
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Old 08-22-2006, 11:17 AM   #16
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HAHAH, LOL, that is me in the flip flops holding the turbo.....
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Old 08-22-2006, 12:04 PM   #17
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very good detailed instructions/info and pictures.

have a blast with your car!!
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Old 08-22-2006, 12:08 PM   #18
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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
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Old 08-22-2006, 12:38 PM   #19
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Me too. I am always working i flip flops.
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Old 08-22-2006, 08:30 PM   #20
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Nice write-up tankerwrx. you better keep that thing out of cincy though, cause I've got a set of flip flops and some tools and now I have step-by step instructions to remove and replace in my car.
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Old 08-22-2006, 08:50 PM   #21
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Pill story continues

Finally source #57 bit at Grqainger - long drive to get there - have to set up a commercial account etc. They forgot to ship it so I went home empty except for the $150 in tools I decided I needed badly

Get bit shipped in - need something to chuck it in -

Lucky go to Lowes and get a Dremel chuck - another $10

Get home - all good - take pill out of WRX hose and drill a nice crooked hole that instantly siamesed -oops

Take pill out of line that is on car that came with VF-39 turbo - it is ALREADY BIGGER THAN 0.043" Bwahahahahahahahaha!!!!

still boost spiking though - meh - need a tune
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Old 08-22-2006, 09:06 PM   #22
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Excellent job! Thank you for the write up!
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Old 08-22-2006, 09:11 PM   #23
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Just wanted to add a tip. If you pull the oil return line off of the block and attach it to the turbo, you can position the hose much easier where it connects to the block than where it connects to the turbo.

You can either (from the top) wrap a hand around the back/underside of the uppipe, or from underneath, fit one hand on the left through the subframe and one hand around the other side of the uppipe.

Much easier then trying to get the hose onto the turbo drain and having no room to reach it.
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Old 08-23-2006, 10:39 AM   #24
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Quote:
Originally Posted by compressor_guy
Nice write-up tankerwrx. you better keep that thing out of cincy though, cause I've got a set of flip flops and some tools and now I have step-by step instructions to remove and replace in my car.
Funny thing is that car will be in Cincy soon. No really. I deploy to Iraq this fall and my parents will be holding it for me.
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Old 08-23-2006, 08:58 PM   #25
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I will be swapping in a Vf39 this weekend. I would like to know, what is the EASIEST way to keep the car from starting so I can prime the turbo?
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