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IAG -ENG-7251 Installation Manual

Competition series air / oil separator (aos) for 2017 sti

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IAG Competition Series Air / Oil Separator (AOS) For 2017 STI
Part# IAG-ENG-7251
Tools Required: Ratchet, torque wrench, extensions,
needle nose pliers, hose cutter, snips/scissors, flat head
screw driver, hose clamping pliers
Sockets: 10mm, 12mm, ¼" allen,
Wrenches: ⅞", 8mm, 10mm, 19mm 3mm allen, 5mm allen,
pry bar,
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.
Note: The 2015+ STI cars are equipped with a "noise
symposer" engine sound enhancing device that connects
the intake to the firewall. These instructions do not cover
the removal process of this device. Usually this device is
already bypassed by the time an AOS is required.
Parts List
Part Name
Air/Oil Separator
Oil Drain Hose Assembly
Top Coolant Hose Assembly
Bottom Coolant Hose Assembly
Discharge Hose
Block Breather Hose
Valve Cover Breather Hose
Block Drain Replacement Hose
Mounting Bracket
90° 5/8" Plastic Fitting
PCV Replacement Fitting
Comp Series Upper Breather Fitting
Fasteners for Breather Top Fitting
AOS Drain Fitting
Spring Clamps
6x10mm Bolt
½" High Temp Rubber Cap
5
/
" High Temp Rubber Cap
8
P
P
R
R
8" Zip Tie
11" Zip Tie
IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com
Quantity
Notes
1
1
26" Hose Length
1
20" Hose Length, ½" I.D., -8ORB
1
20" Hose Length, ½" I.D., -8ORB
1
58" Hose Length, 1" ID
1
25" Hose Length,
1
74" Hose Length, ½" ID
1
2" Hose Length, ¾" I.D.
1
1
Block Breather Fitting
1
"Y" Fitting
1
Preinstalled
2
M4x8mm / preinstalled
1
Preinstalled
2
Coolant Hose Spring Clamps
3
Mounting Bracket Hardware
1
1
16
1
5
/
" ID
8
P
P
R
R
1

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Summary of Contents for IAG IAG-ENG-7251

  • Page 1 Spring Clamps Coolant Hose Spring Clamps 6x10mm Bolt Mounting Bracket Hardware ½” High Temp Rubber Cap ” High Temp Rubber Cap 8” Zip Tie 11” Zip Tie IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 2: Driver Side

    Press the connector clip in and pull the black portion of the sensor from the white portion as shown. Driver Side IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 3 Driver Side Passenger Side Passenger Side IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 4 5. Using a 12mm socket, remove the (x2) 12mm bolts that hold the hard breather lines to the intercooler. Then remove the assembly from the vehicle. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 5 (BOV) to the intercooler. You can leave the BOV where it sits. Be careful not to lose or damage the gasket. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 6 In addition, remove the driver side intercooler bracket. It is held on by (2) 12mm bolts at the intake manifold. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 7 9. Using a flat head screw driver or 8mm nut driver, loosen the hose clamp at the intercooler outlet silicone coupler. Then loosen the hose clamp at the intercooler inlet. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 8 11. Locate the passenger side Crankcase Ventilation Sensor (Black) and using a small flat head screw driver carefully press in and free the harness clip from the plastic vent tube. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 9 (the one that is closest to the front of the car). Pull the hose off the valve cover port. Use a flat head screw driver if necessary to help free the hose off the port. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 10 13. Repeat the process on the driver side forward most valve cover breather hose. Remove the driver side hose from the engine bay. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 11 15. Remove the small pinch clamp and hose from the PCV vacuum nipple under the throttle body on the intake manifold using needle nose pliers. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 12 ¾” drain hose. If the OEM drain hose is in good condition you will reuse it. We have supplied you with a new drain hose if the OEM unit is worn or damaged. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 13 The plug comes with thread sealant on it. Torque the plug to 15 . Do not over torque as the intake manifold can be damaged. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 14 Depending on the removal process it may be on the PCV assembly or still located on the engine. Install the supplied plastic drain fitting into the ¾” drain hose as shown. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 15 Supplied drain fitting shown left Drain fitting installed into the OEM ¾” hose Drain fitting and hose install port location IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 16 Remove the driver side mini wiring harness (Blue) from the (Black) Crankcase Ventilation Sensor using a small flat head screw driver to unclip the harness from the sensor as shown. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 17 Crankcase Ventilation Sensor mini connector harness as shown. Tape the connector end with electrical tape to prevent exposure to the elements. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 18 IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 19 23. Reinstall the mini Crankcase Ventilation Sensor harness onto driver side hose as shown by reusing the OEM zip tie. Then plug the electrical connector back into mini harness. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 20 Tape the connector end with electrical tape to prevent exposure to the elements and tuck it out of the way. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 21 Cap off the white sensor using the supplied 5/8” vinyl cap and 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 22 IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 23 Crankcase Ventilation sensor harness connector from the plastic crankcase breather hose fitting located at the passenger side, front, intake manifold. Then pull the crankcase breather hose and fitting free from the engine. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 24 28. Using the supplied 5/8” vinyl cap, cover the hole in 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 25 Then insert the jumper into the passenger side front connector harness as shown. Tape the connector end with electrical tape to prevent exposure to the elements and tuck it out of the way. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 26 OEM main wiring harness electrical tape at firewall as shown. (Harness is folded over itself under the tape). Refer to picture. Main wiring harness braket clip IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 27 Main Harness wiring Main wiring harness shown after cutting tape IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 28 32. Remove main wiring harness bracket using 10mm socket and ratchet, it is held on by (1) 10mm bolt located on the passenger side strut tower. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 29 Next push the rear 3 brake lines back towards the firewall to make space for the AOS. If necessary a pry bar and cloth can be used to carefully manipulate the lines. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 30 34. Using a pop clip tool, free the wiring harness loom from the passenger side bracket located next to the turbo. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 31 35. Next install the (2) AOS coolant lines onto the AOS (Lines come pre-assembled). Thread them on by hand and tighten using 7/8” open end wrench. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 32 AOS. Start the upper M6x10mm bolt first then start the lower M6x10mm bolt. Once both bolts have been slightly threaded use a 10mm wrench to finish tightening them. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 33 39. Use a 10mm socket and ratchet to remove the (1) 10mm bolt from the power steering line bracket located on the passenger side strut tower. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 34 Then finish tightening the 10mm bolt. Finally press down on the harness and slightly bend the bracket downwards as shown. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 35 42. To minimize coolant loss, pinch off the lower coolant hose that connects the turbo to the cylinder head using hose clamping pliers. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 36 AOS coolant line. Then slide hose over the expansion tank port barb and secure the line with the clamp. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 37 Trim the line to fit onto the upper coolant turbocharger hard pipe. Yellow stripe shows routing to turbo coolant line IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 38 46. Using pinch pliers slide the OEM clamp down the OE upper turbo coolant line. Next slide the new supplied pinch clamp onto the lower IAG AOS coolant line at the turbo. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 39 If substantial coolant is lost, bleeding the coolant system is required to avoid overheating. Secure the pinch clamp and remove the OEM line from the vehicle. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 40 Once the hose is in place install a zip tie to secure the hose and trim the excess. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 41 IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 42 90° fitting, then slide the remaining length of 5/8” hose on the other side of the fitting. Zip tie the hoses on to the 90° fitting and trim off the excess. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 43 Make sure to trim the excess zip tie lengths off. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 44 AC line and over top the fuel injector cover bracket until it meets the valve cover port. Slide the hose onto the port and secure it with a zip tie. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 45 Then install the hose onto the port. Install a zip tie on the hose at the center fire wall AC bracket as well as at the center AOS port. Trim off the excess. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 46 Finally slide it onto the passenger side valve cover breather port and secure it with a zip tie and trim the excess off. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 47 Attach the upper portion of the line to the upper AOS breather port and secure it with a zip tie trimming the excess. IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 48 58. Before proceeding, please look over the check list below: C heck Over List Are all coolant fittings tight? Are (2) coolant clamps correctly fitted on the turbo coolant IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com...
  • Page 49 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...