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Old 04-03-2005, 12:50 PM   #1
kennyvb
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Default USDM STi Intercooler on 05 WRX

I recently purchased an 05 USDM STI intercooler for my 05 WRX. Once again, I confirmed it was NOT a direct bolt-on as covered many times. I was fully aware of this and the mounting option I believe pioneered by BIGSKYWRX as seen on http://www.clubwrx.net/forums/showthread.php?t=51348. Even though welding new bolt holes in the factory mounts (same for WRX & STI) wouldn't be terribly difficult, I decided to see if could utilize factory mounts and correct the STI's throttle body and VF39 turbo positioning differences to the WRX TB and turbo with a new coupler and elbow off the solid y-pipe.





It works so far. The TB to I/C coupler is a Greddy ~65mm ID, 75mm long silicone piece I purchased for less the $10. The stock length was ~47mm. The elbow off the hard y-pipe to my stock turbo is a Turbonetic nitrile elbow 2" x 90' (P/N 30208). About 10mm was cut off one end of the elbow to fit.

Since this mounting location makes the intercooler sit closer to the firewall (same location in an STI), I had to bend the hard A/C lines for clearance.
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Old 04-03-2005, 01:29 PM   #2
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why not just get the stock STi brackets ?
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Old 04-03-2005, 02:26 PM   #3
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I'm still wondering how I simply bolted a 2004 USDM STi intercooler onto my 05 WRX without any problems at all.
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Old 04-03-2005, 03:15 PM   #4
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Quote:
Originally Posted by ronf
why not just get the stock STi brackets ?
The STI brackets and the 04 wrx brackets are the same. I've done this same install and it works with longer hoses as noted above or the bracket mod also noted above. I don't know how some 04/05 wrx owners got them to fit w/o doing one of the above. I was able to play with it and get one intercooler mount to bolt up but not both. When I bought my USDM STI intercooler I also got the brackets and compared them with my wrx brackets and they are the same.
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Old 04-03-2005, 03:48 PM   #5
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Yes the brackets are identical- same part#'s.

kennyvb- good job!- there are always more than one way to skin a cat

You've also saved a little $ on the seal as well- I've documented that the v8 seal needs to be replaced w/ the v7 one to get the correct seal when using different reloacating brackets (as the IC is moved slightly ahead as it was w/ the v7 pre- throttle by wire).

The other thing I've thought of was that the new "jdm" STi intercoolers are now going to have the same fitment issues (I'm assuming they've also moved to fly be throttle as well). The "old" v7 STi ones bolted right in (and were slightly bigger to boot)

Big Sky
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Old 04-10-2005, 07:19 PM   #6
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Thanks Big Sky.

By request...here's a picture indicating two areas that might rub. Do your best to bend the heard lines out of the way. I could hear them rub when they did so I rebent and zip-tied (not much tension) for good measure. No rubbing after that (so far).



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Old 04-10-2005, 07:28 PM   #7
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hacked splitter...still to find/fit bellows



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Old 04-10-2005, 07:34 PM   #8
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Even in the "forward" position there is still a little chance for rubbing the AC lines- I covered mine w/ split rubber fuel line to insure no problems.

Your running the stock scoop?
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Old 04-10-2005, 07:58 PM   #9
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I marked the problem areas with a sharpie to see if it'd rub off, and it looked good. But yes, I will still probably wrap the lines with something, too. Trying to find something as thin as possible to keep "passive" protection. There's about 1 cm clearance on both areas, and I was thinking something like teflon or electrical tape (although they offer very little protection)

Yes, I wanted to retain the WRX hood scoop. I tought about getting the USDM STI splitter and bellows but I'd still have to hack that as well. That was probably a better option but I will see if I can fit the USDM STI bellows to this splitter.
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Old 04-10-2005, 08:11 PM   #10
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My wife wishes I retained the stock scoop It was a easy fit w/ the STi splitter/seal (and scoop) though. You now have the problem of sitting back further back than you originally did w/ the oe IC too- as far as your seal goes.

I've got a v8 STi seal that locates the seal rearward, PM me if your interested.

Mike
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Old 04-14-2005, 12:25 AM   #11
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Does anyone have the P/N of the JDM Splitter to match the 02/03 hood opening for the STI? I saw the bellows P/N posted already. Also, I saw a 04/05 STI splitter mounted to an 03 hood, but it looked like they had sliced the splitter between the IC opening and the turbo cooling air opening to "shorten" the overall width. Has anyone else tried this?

Greg
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Old 04-14-2005, 09:12 AM   #12
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Quote:
Originally Posted by kennyvb
...But yes, I will still probably wrap the lines with something, too. Trying to find something as thin as possible to keep "passive" protection. ...
I've used split rubber hose (sometimes called heater or emissions hoses) from my local auto parts place for such purposes. Just an idea.
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Old 04-14-2005, 10:34 AM   #13
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Quote:
Originally Posted by hyedracyl
Does anyone have the P/N of the JDM Splitter to match the 02/03 hood opening for the STI? I saw the bellows P/N posted already. Also, I saw a 04/05 STI splitter mounted to an 03 hood, but it looked like they had sliced the splitter between the IC opening and the turbo cooling air opening to "shorten" the overall width. Has anyone else tried this?

Greg
No part #, but Dave at rallispec carries them- he has bot the "regular" splitter and the RA one- which sports only one nozzle hole and is aluminum (vs sheet metal).

I wouldn't think the v8 splitter wouls be such a good fit on the v7 scoop as the v8 scoop is a good inch (or more taller)- also a slightly different shape- could be made to work probably- but the v7 is direct and correct fitment.
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Old 04-14-2005, 02:04 PM   #14
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Thanks for the info BIGSKYWRX.

I have the fiberglass replica of the USDM STI scoop that is sold by Gruppe-S, so the taller splitter shouldn't be a problem. They also had a splitter which looked custom made for the 02/03 hood, but it did not appear to have the sheet metal arangement necessary to support the V7 bellows. Without that, I don't want it.

The picture that I saw of the 04/05 "cut" splitter was also mounted on a 03 fitted with the larger (later STI model) scoop design. I'll look up the parts that you mentioned and see what I think is the best immediate purchase. Thanks.

Greg
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Old 04-14-2005, 02:56 PM   #15
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Quote:
Originally Posted by jac04
I'm still wondering how I simply bolted a 2004 USDM STi intercooler onto my 05 WRX without any problems at all.
someone sold you a wrx intercooler with "STi" painted on it.
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Old 04-14-2005, 04:37 PM   #16
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thanks for the pictures, I am waiting on my longer TB hose and I will be doing this as well. sometime next week I think. I've got the sti scoop on, sti tmic on, got the sti splitter bellows waiting in the garage for the hose to come in the mail! can't wait either!

thanks also to everyone that knows that the bracketry is the same from STI to WRX (04+)for saying as much. I have no idea where the myth got started or whether people just say it because it may have been true previously. but those of us that know need to be vigilant in stopping it! hehehe

seriously though, it is frustrating though when you have actually gone and measured an STI right next to your car and verified that the brackets are the same, measured the placement of the IC, verified the placement of the bellows, measured almost anything that will make a difference when swapping a regular IC with a USDM STI IC, and then someone says you are wrong and they have only heard what someone else said.

and thanks for posting the pics of the AC lines, some good ideas to work around the possibility of having a car with no AC.

I think I am going to take pictures of me measuring all the fitment, and when I see someone saying it I can just link them. unabomber style
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Old 04-14-2005, 10:43 PM   #17
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Quote:
Originally Posted by kennyvb
Trying to find something as thin as possible to keep "passive" protection. There's about 1 cm clearance on both areas, and I was thinking something like teflon or electrical tape (although they offer very little protection)
Try some regular old split-loom for wiring...I forget what size, but I've covered most of my AC lines with it, including the bare ones running near the battery (imagine tapping one of those with +12V by accident ). Give the ends a few wraps with electrical tape...I used black, and it's barely noticeable--just looks natural.
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Old 04-16-2005, 05:43 PM   #18
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Well, I hacked up the extra bracket set that I received with the IC and had nuts welded to them in the locations necessary to allow the STI intercooler to be mounted (into a position that would simulate the stock 02 WRX intercooler).

I went to the dealer and examined an STI, and found little reason to believe that the current version STI splitter won't fit on an 02 hood either. I mean, it was close dimensionally EVERYWHERE that the mounting bolts were involved. The height of the ducting is definitely higher, but I don't think that my "replica" scoop is going to have a problem accommodating the height of the current USDM splitter.

I'm going to just order the current USDM splitter and V7 bellows and see how everything shakes out. I was surprised though to find that the opening in the V8 bellows only measure 5.5" fore/aft (about 17.5" side to side). I would have expected another half inch or so to accommodate the larger intercooler.


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Old 04-17-2005, 12:11 AM   #19
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I might try an experiment of my own- a v7 splitter under the 04 (WRX) scoop.
I had a v7 hood scoop on my old 02 WRX and if memory serves me correctly- the v7 STi scoop is very close (in height, not shape) to the 04 scoop- I'm thinking the splitter should fit under it.
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Old 04-17-2005, 02:10 AM   #20
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After running all of the guage wiring into the passengers compartment (that only took 3 years...), I installed my "damaged" STI intercooler and bolted it into place. I'll get the car out tomorrow for a test drive and see if the IC will hold pressure under boost. The IC is very solid in its current position, and the regular 02 scoop bellows is currently very well positioned to direct cooling air over the surface of the STI IC.

Greg
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Old 05-15-2005, 12:01 AM   #21
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Quote:
Originally Posted by BIGSKYWRX
I might try an experiment of my own- a v7 splitter under the 04 (WRX) scoop.
I had a v7 hood scoop on my old 02 WRX and if memory serves me correctly- the v7 STi scoop is very close (in height, not shape) to the 04 scoop- I'm thinking the splitter should fit under it.
It works (w/ a smidge of fabbing)

details here:

http://www.clubwrx.net/forums/showthread.php?t=104742
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Old 05-15-2005, 01:18 AM   #22
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Good work, Big Sky.

I actually "caved" and sourced a regular V8 scoop and splitter. Like you predicted, the USDM V8 bellows work perfectly with how I mounted the intercooler.
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Old 05-15-2005, 11:54 AM   #23
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Great! It's nice to start getting these things nailed down
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Old 05-31-2005, 02:53 PM   #24
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Got the longer hoses for the 90deg elbow and throttle body, went it fine, the only issue was the AC lines. I know it's not supposed to do much as in the way of power but the car does seem to run a little better. May the car is learning with the Cobb AP stage 1?????

Thanks to all the predecessors for leading the way for an easy upgrade.
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Old 05-31-2005, 04:15 PM   #25
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So, lets get this all in one place (feel free to correct at will). The things we've found out so far are...

Hose Mod:If you install the V8 STI I/C in an 04+WRX you can use the stock mounts but you will need to buy longer hoses to fit. Those hoses are a Greddy ~65mm ID, 75mm long silicone piece for the throttlebody hose and the elbow off the hard y-pipe to the stock turbo is a Turbonetic nitrile elbow 2" x 90' (P/N 30208).

Bracket Mod:
You can also install the V8 STI I/C on an 02-05WRX by doing the "bracket mod." If you do it this way, you can retain stock hoses?? (That part I'm a little unsure of) The mod can be found at: http://www.clubwrx.net/forums/showthread.php?t=51348.

Now, as far as scoop/splitter/bellows combos go, I'm still a little unsure of what you guys got, but here's what I got out of it...

For 04+WRX's with the "hose mod":
If you want to retain the stock scoop: buy the V7 scoop and bellows.

If you want to have V8 STI scoop: buy V8 scoop and bellows.

For 04+WRX's with the "bracket mod":
If you want to retain stock scoop, mod 04 WRX scoop and bellows accordingly (because placement of brackets will be closer to stock I/C placement)

If you want to have V8 STI scoop: buy the V8 splitter/bellows and hack accordingly to make fit (because V8 stuff will not line up properly if the V8 STI I/C is in the stock 04+ place??)

For 02-03 WRX's:
If you want to keep stock scoop: buy V7 splitter and bellows, but you must hack the V7 splitter because it is taller than normal WRX splitter

If you want to have V7 scoop: source V7 splitter and bellows



Just trying to see if this is what we've learned so far. I'm expecting to do a V8 STI I/C swap sooner than later as well, so if any of this information is wrong, Post/PM me and I will change this post.

Aaron
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