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IAG -ENG-7252 Installation Manual

IAG -ENG-7252 Installation Manual

Competition series air / oil separator (aos) for 2015-16 wrx

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IAG Competition Series Air / Oil Separator (AOS) For 2015-16 WRX
Part# IAG-ENG-7252
Tools Required: Ratchet, torque wrench, extensions,
needle nose pliers, hose cutter, snips/scissors, flat head
screw driver, hose clamping pliers, pop clip pliers
Sockets: 10mm, 12mm, 13mm, 19mm,
Wrenches: ⅞", 8mm, 10mm, 13mm, 3mm & 5mm allen,
Other: Electrical Tape
Congratulations on the purchase of your Air/Oil Separator
(AOS) and thank you for choosing IAG Performance. This
installation manual is intended to guide you through the
removal of the factory PCV system and the installation of
the IAG AOS. If you already have an aftermarket catch can
or AOS installed, please consult the specific instructions for
your hardware to aid in its removal.
Parts List
Part Name
Air/Oil Separator
Top Coolant Hose Assembly
Bottom Coolant Hose Assembly
AOS Vent Hose
Block Breather Hose Assembly
Drain & Lower Breather Hose Assembly
Comp Series Upper Breather Fitting & O-ring
M4x6mm Fasteners for Breather Top Fitting
AOS Drain Fitting
½" Spring Clamp
Mounting Bracket
M6x12mm
6x10mm Bolt
5
/
" High Temp Rubber Cap
8
P
P
R
R
8" Zip Tie
11" Zip Tie
ECU Relocation Bracket
6x20mm Bolts
6mm Washers
⅜" Plastic Plug
⅜" NPT to ⅝" Brass Barb Fitting
IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com
Quantity
Notes
1
1
43" Hose Length, ½" I.D., -8ORB
1
15" Hose Length, ½" I.D., -8ORB, ½" Straight Plastic Barb
1
55" Hose Length, 1" ID
1
2.5" Hose to 90° Fitting to 44" ½" Hose
1
90° to Y Fitting / (x2) Hoses - 15" & 21"
1
2
Preinstalled
1
Preinstalled
1
Coolant Hose Spring Clamp
1
2
Mounting Bracket
3
Mounting Bracket
2
(x1) Preinstalled on AOS Can
15
1
Used to mount vent hose under the car
1
2
ECU Bracket
2
ECU Bracket
1
Blocks PCV Hose
1
Block Breather Fitting PCV Replacement Fitting
1

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Summary of Contents for IAG IAG-ENG-7252

  • Page 1 6x20mm Bolts ECU Bracket 6mm Washers ECU Bracket ⅜” Plastic Plug Blocks PCV Hose ⅜” NPT to ⅝” Brass Barb Fitting Block Breather Fitting PCV Replacement Fitting IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 2 2. Disconnect the negative battery terminal using a 10mm wrench. 3. Using pop clip pliers remove the upper engine cover’s (2) pop clips, then remove the cover from the vehicle. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 3 IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 4 Next disconnect the electrical connector by pinching the plastic spring clip in and pull the connector free. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 5 6. Next using a 3/8”, ratchet and 10mm socket remove the (2) 10mm bolts from the top passenger side radiator fan. Carefully lift the radiator fan assembly from the vehicle. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 6 (Optional) Some find this easier: You can leave the BOV attached to the boost pipe and release the pinch clamp on the inlet and remove the BOV with the boost pipe. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 7 Then remove the pipe from the intercooler. If the rubber insert comes out reinsert it back into the pipe. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 8 10. Loosen the hose clamp on the intercooler outlet. Then remove the intercooler from the vehicle being careful not to damage the fins or ac lines. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 9 Then loosen the spring clamp that holds the breather to the inlet pipe. Finally remove the breather pipe from the engine retaining clip and remove the breather pipe from the engine. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 10 13. Using the supplied ⅝” vinyl cap, cover the barb hole on the inlet and secure it with a zip tie. Trim the excess of the zip tie with snips or scissors. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 11 EGR valve and intake manifold. Be careful not to lose or damage the metal gasket at the EGR valve as it is reused. Remove the pipe from the vehicle. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 12 15. Using hose clamp or needle nose pliers loosen the spring clamp that attaches the PCV hose to the PCV valve. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 13 17. Using a 19mm socket, 8” extension and ratchet remove the PCV valve from the engine short block. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 14 18. Next thread into the block the supplied ⅜” NPT to ⅝” brass barb fitting. Using the 19mm socket, ratchet and extension torque the fitting to 15ft / lbs. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 15 (2) 10mm nuts that hold the ECU to the bracket. Then pull the ECU free from the bracket and place it aside in the engine bay. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 16 21. Remove the (2) 10mm bolts that hold the ECU bracket to the passenger side strut tower and frame rail as shown. Then remove the bracket from the vehicle. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 17 Next using a 10mm socket and ratchet remove the 10mm bolt that holds the ground wire to the upper frame rail. Then using needle nose pliers pull the white retaining clip from the frame rail. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 18 23. Relocate the ground wire to the lower frame bolt hole as shown using the OEM bolt. Tighten the bolt using a 10mm socket and ratchet. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 19 8” extension and ratchet tighten the 10mm bolt on the top frame rail. Then using a 10mm socket and ratchet tighten the 10mm bolt on the side of the frame rail. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 20 25. Using a 10mm socket and ratchet remove the 10mm bolt that secures the wiring harness onto the ECU. Next remove the wiring retaining clip from the bracket and remove the bracket from the vehicle. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 21 29. Locate the Competition Series upper breather fitting and O-ring. Fit the O-ring onto the fitting as shown. Then insert the fitting on the top of the AOS. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 22 10mm nuts securing the wiring harness bracket. Unclip the harness from the bracket and remove the bracket from the vehicle. Next unclip the harness from the brake line bracket. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 23 33. Using a pry bar and cloth carefully pry and bend the brake lines up next to the strut tower. Next push the rear 3 brake lines back towards the firewall to make space for the AOS. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 24 AOS. Start the upper M6x12mm bolt first then start the lower M6x12mm bolt. Once both bolts have been slightly threaded finish tightening them. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 25 35. To minimize coolant loss, pinch off the coolant hose that connects the turbo to the engine coolant port and the lower coolant hose that connects to the EGR tube using hose clamping pliers. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 26 AOS coolant hose. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 27 AOS upper coolant hose then route the hose as shown to the turbo coolant port. Secure the hose to the turbo coolant port with the spring clamp using pliers. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 28 AOS install is complete. 40. Locate the block breather / drain hose assembly. Route the shorter of the (2), ½” hoses thru the hole on the intercooler mounting bracket. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 29 Attach the cap to the lowest of the three AOS ports on the can. Secure the cap with a zip tie and trim off the excess. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 30 Attach the line to the lower drain port on the AOS. Make sure the line is not kinked or obstructed. Secure the line with a zip tie and trim the excess. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 31 OEM 12mm bolts. Torque is 14ft. / lbs. *Make sure before installing the EGR pipe that the OEM O-ring is in place on the intake manifold. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 32 46. Route the long ½” breather assembly hose under the intake manifold towards the brake master cylinder. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 33 AC line at the fire wall. Trim the excess off the zip ties. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 34 Make sure the line is free of any kinks and secure the line to the transmission cross member as shown using an 11” zip tie. Snip the excess off the zip tie off. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 35 50. Reinstall the intercooler, boost pipe, radiator fan, intake air duct and engine cover using the OEM hardware. Reattach the negative battery terminal. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 36 After the engine has heat cycled, you can check the coolant level and replace any coolant that was lost during installation. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...