4th Gen intercooler failure...

[LunchBox04V]

Great to get the early years of a new model. lol I have been running a COBB stage 2 for about a year. I noticed that, after my open track day, I was down on boost (2-3psi) and down on MPG (3-4). Was a little worried I did something terrible until I looked at the intercooler. I had bent two of the metal tabs that hold the plastic end tanks to the core. I found out that this failure is common on cars from no mod, to stage 2+.
So... heres the plan:
1) I'm going to the the LegacyGT fix and use some JB Weld to strengthen the ok tabs. I'll reconnect the slightly bent tabs and JB Weld them as well.
2) Put either an AVO or Perrin intercooler on my Christmas list.

My questions are,
1) Which JB Weld should I use? (Or other product... Never used JB before)
2) Would I need a new tune to account for a new intercooler? (Or will the computer and stage 2 COBB handle that)

Thanks for the input, and hope to hear some great suggestions or tips. Also, be warned for the other 4th gen guys our there!

[chrish8r]

There is that "bullet-proof" intercooler mod I have seen on legacygt. Its metal bars that go around the fins and have a metal ziptie holding them tight.

If you are waiting til christmad for a new intercooler, Grimmspeed is working on making a legacy gt tmic( saw thread on nasioc with prototype pics).

[LunchBox04V]

I have seen the bulletproof mod as well. I guess I didn't know which way to go to be honest. Lol I'm rather not spend the $650 for an AVO... But I know it's the proper way to fix it and fix it right. Gotta love being underpaid! Haha

[chrish8r]

Im defintely not looking forward to buying a new intercooler. They are so expensive.

[LunchBox04V]

So... Just went and tried to push the tabs that were deformed back down (and I pushed super light) and they broke off. So much for the cheap fix. Anyone know where I can get an AVO for cheap? Best I saw online was $650.

[chrish8r]

After reading through most the "bullet-proof" mod thread, Im fairly certain I am going to try and go with that. Im going to try and do it myself without the kit(buy some aluminum channel and steel zipties). That should only cost ~$30 so it wouldn't be a big hit on the bank account.

[LunchBox04V]

I wish I had looked into this before my intercooler gave up the ghost. I'll snap some pictures when I remove it, but mine failed where the bullet proof mod does not protect. Next to the turbo, on the vertical section (where there are only 3 clips). I'm lucky in that I'm only dropping a few psi under full boost.

[LunchBox04V]

Sigh... Well I broke down and did it today. Bought the AVO. Should be here by Friday. Sad to see the money go, but WOOT! for new top mount! Lol

[LunchBox04V]

Ok... So here is the update...
The Good:
- The new AVO intercooler is AWESOME! I've gained about 2psi under boost. If "feels" (hate saying that) like it spools faster.
- Install was pretty straight forward, despite the instructions being a little vague at times.

The Bad:
- I still have a vacuum/boost leak... GRRRRRR!!!!!

Testing:
- After doing a little looking I was able to find a helpful post regarding vacuum leak testing. I do have a COBB AccessPORT, and was able to pull the "A/F LEARNING 1 A" reading. I guess if you have a vacuum leak at idle it will max out at 15% (max allowed adjustment value). Mine was reading that... Now its just a matter of tracking it down. I have checked all the normal and easily accessible vacuum lines (including the blue one under the intercooler) and they appear to be connected and in good order.

So, I have more boost, but it is still unstable. The original intercooler had been repaired before (previous owner, and I didn't know that it had been... used the JB Weld as well). I'm going to take the car to Oakos Subaru (tuner shop and parts dealer) and have them run a pressure test on the intake. I "think" my intercooler to throttle body hose might be the issue. I couldn't even get to the front hose clamp (it was tight). It may also be a cracked/aged line. The leak test will show where the problem is.

[chrish8r]

Ive read a lot of issues with the throttle body hose connection. Either the hose is torn slightly or even folded over on the lip.

Im gonna check my car using the "a/f learning 1 a" to see if i have a leak or not.

[LunchBox04V]

I'm probably going to get the AVO intercooler to throttle body hose. And your 100% correct, the thing normally folds or rips. I also looked at the "A/F LEARNING." It was at 14.89%... the tech I talked to also agreed with my simple diagnosis (coupled with the 2-4mpg loss...)

[chrish8r]

Did you get everything running alright? Any more leaks?

[Merc6]

How did this turn out? The throttle body hose had a little dot that needs to be up or it gets hairy. I have a Perrin and it feels like every install it goes on a different way. My leaks were at the blue tee under the tmic. I got a turkylord tee now in place of it.