IAG IAG-ENG-7252, Installation Manual

Page 1: ...ns for your hardware to aid in its removal Parts List Part Name Quantity Notes Air Oil Separator 1 Top Coolant Hose Assembly 1 43 Hose Length I D 8ORB Bottom Coolant Hose Assembly 1 15 Hose Length I D 8ORB Straight Plastic Barb AOS Vent Hose 1 55 Hose Length 1 ID Block Breather Hose Assembly 1 2 5 Hose to 90 Fitting to 44 Hose Drain Lower Breather Hose Assembly 1 90 to Y Fitting x2 Hoses 15 21 Com...

Page 2: ...al Please read through the entire removal instructions before proceeding 1 The engine needs to be completely cool before beginning work 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 ...

Page 3: ...IAG Performance 1203 Baltimore Blvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 3 ...

Page 4: ... upper core support then remove the duct from the vehicle 5 Some may find it easier to access things by removing the passenger side radiator fan This can be done by locating the small grey electrical connector on the lower passenger side radiator fan Next disconnect the electrical connector by pinching the plastic spring clip in and pull the connector free ...

Page 5: ...ster MD 21157 Ph 410 840 3555 www iagperformance com 5 Shown disconnected above 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 ...

Page 6: ...s that hold the boost pipe to the turbo Then using an 8mm socket loosen the clamp that holds the blow off valve This can be done from above or below the car If removing from underneath the car remove the OEM belly pan 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 ...

Page 7: ... head screw driver or 8mm socket and ratchet loosen the hose clamp that holds the boost pipe to the top mount intercooler Remove the boost pipe from the vehicle by first pulling it free from the blow off valve Then remove the pipe from the intercooler If the rubber insert comes out reinsert it back into the pipe ...

Page 8: ... 3555 www iagperformance com 8 9 Using a 12mm socket remove the intercooler mounting bolts on either side of the intercooler 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 ...

Page 9: ...clips that hold the breather pipe to the intake manifold 12 Using hose clamp pliers or needle nose pliers loosen the spring hose clamp on the breather pipe as shown 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 ...

Page 10: ...altimore Blvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 10 13 Using the supplied 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 ...

Page 11: ...www iagperformance com 11 14 Using a 12mm socket 3 extension and ratchet remove the 4 12mm bolts that hold the EGR pipe onto the 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 ...

Page 12: ... Performance 1203 Baltimore Blvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 12 15 Using hose clamp or needle nose pliers loosen the spring clamp that attaches the PCV hose to the PCV valve ...

Page 13: ...55 www iagperformance com 13 16 Pull the PCV hose free from the PCV valve and insert the plastic plug into the hose Next using the OEM spring clamp secure the plug in the hose 17 Using a 19mm socket 8 extension and ratchet remove the PCV valve from the engine short block ...

Page 14: ... Baltimore Blvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 14 18 Next thread into the block the supplied NPT to brass barb fitting Using the 19mm socket ratchet and extension torque the fitting to 15ft lbs ...

Page 15: ...ring harness retaining clips from the ECU mounting bracket Using needle nose pliers squeeze the locking tabs to free them from the bracket 20 Using a 10mm socket ratchet and 3 extension remove the 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 ...

Page 16: ...timore Blvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 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 ...

Page 17: ... com 17 22 Pry out the small plastic plug located under the ground wire on the passenger side frame rail 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 ...

Page 18: ... 1203 Baltimore Blvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 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 ...

Page 19: ...he supplied ECU relocation bracket Attach the bracket using the 2 10mm bolts that held the original bracket to body of vehicle as shown Using a 10mm socket 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 ...

Page 20: ...r MD 21157 Ph 410 840 3555 www iagperformance com 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 ...

Page 21: ...s to the bottom of the AOS Thread them on by hand and tighten using open end wrench 28 Install the bracket onto the AOS using the 3 small allen bolts as shown The third hole from the bottom of the AOS should be oriented to the lowest allen bolt hole on the bracket Tighten the three allens Note in April 2016 the mounting bracket for the AOS was changed This affected routing of the wiring harness So...

Page 22: ...e the 2 supplied 4mm x 6 allen bolts and using a 3mm allen wrench thread the bolts thru the breather fitting into the AOS and secure the port fitting 31 Using a 10mm socket and ratchet remove the x2 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 ...

Page 23: ...com 23 32 Now that the harness is free push the harness down towards the frame rail to make clearance for the AOS 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 ...

Page 24: ...stall the AOS using the two holes on the strut tower shown in the picture Guide the lower and upper coolant hose underneath the main wire harness while installing the AOS Start the upper M6x12mm bolt first then start the lower M6x12mm bolt Once both bolts have been slightly threaded finish tightening them ...

Page 25: ...ster MD 21157 Ph 410 840 3555 www iagperformance com 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 ...

Page 26: ...3555 www iagperformance com 26 36 Using needle nose pliers remove the spring clamp at the turbo coolant port Next loosen the spring clamp on the coolant line at the engine and rotate the hose towards the strut tower so that it can meet up with the lower AOS coolant hose ...

Page 27: ...o the lower AOS coolant hose straight fitting Next using pliers and the OEM spring clamp secure the OEM hose to the fitting 38 Slide the supplied spring clamp onto the end of the 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 ...

Page 28: ... 28 39 Remove all the hose clamping pinching pliers If you lost coolant you will have to top it off and bleed the coolant the system when the AOS install is complete 40 Locate the block breather drain hose assembly Route the shorter of the 2 hoses thru the hole on the intercooler mounting bracket ...

Page 29: ...0 hose lines up with the brass barb fitting on the engine block Push the 90 hose onto the brass barb and secure it with a zip tie Trim the excess off the zip tie 41 Locate the supplied cap included with the AOS kit 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 ...

Page 30: ... 840 3555 www iagperformance com 30 42 Locate the AOS oil drain line that runs thru the intercooler support bracket 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 ...

Page 31: ...the hose to the can with a zip tie Next secure the breather hose to the small AC line at the fire wall Make sure the line is free of kinks and is not obstructed Trim the excess off the zip ties 44 Reinstall the OEM EGR pipe and gasket using the 4 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 ...

Page 32: ...Ph 410 840 3555 www iagperformance com 32 45 Locate the AOS breather assembly Install a zip tie loosely onto the short hose end of the breather hose assembly 46 Route the long breather assembly hose under the intake manifold towards the brake master cylinder ...

Page 33: ...ie to the block breather port under the AC compressor as shown Secure the short hose with the zip tie and trim the excess 47 Route the long portion of the breather hose along the firewall to the top port on the AOS as shown Secure the hose with a zip tie at the port and onto the small AC line at the fire wall Trim the excess off the zip ties ...

Page 34: ... get under the car to help guide the hose Attach the upper portion of the line to the upper AOS vent port and secure it with a zip tie trimming the excess 49 Place the vehicle on a lift or on jack stands route the remainder of the 1 breather line under the transmission cross member and along the side of the transmission Make sure the line is free of any kinks and secure the line to the transmissio...

Page 35: ...altimore Blvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 35 50 Reinstall the intercooler boost pipe radiator fan intake air duct and engine cover using the OEM hardware Reattach the negative battery terminal ...

Page 36: ...nk Was any coolant spilled in the engine bay cleaned up Are the hose clamps on the silicone couplers tight Are the following connections zip tied valve cover ports Both connections on the Y fitting that is attached to the block All 3 side ports on the AOS The top breather port 52 After you have reviewed the check list proceed to start the vehicle and check for leaks After the engine has heat cycle...