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IAG IAG-ENG-7251, Installation Manual, Page: 6 / 49

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IAG IAG-ENG-7251 Installation Manual Download Page 6

 

IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com 

6 

 

7. Next pull the brake booster hose free from the driver 

side intercooler clamp.  

 

 

 

 

8. Using a 12mm socket, remove the intercooler mounting 

bolts on either side of the intercooler. In addition, remove 

the driver side intercooler bracket. It is held on by (2) 

12mm bolts at the intake manifold. 

 

 

Summary of Contents for IAG-ENG-7251

Page 1: ...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 Quantity Notes Air Oil Separator 1 Oil Drain Hose Assembly 1 26 Hose Length Top Coolant Hose Assembly 1 20 Hose Length I D 8ORB Bottom Coolant Hose ...

Page 2: ... 08 Install Only URemoval 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 Disconnect the x2 Crankcase Ventilation Sensor electrical connectors located on the driver and passenger side of intercooler Press the connector clip in and pull the black port...

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

Page 4: ...ce com 4 4 Next locate the Crankcase Ventilation Sensor at the front of the engine and unplug it separating the white portion from the black portion 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 ...

Page 5: ...estminster MD 21157 Ph 410 840 3555 www iagperformance com 5 6 Using a 12mm socket remove the 2 12mm bolts that hold the blow off valve BOV to the intercooler You can leave the BOV where it sits Be careful not to lose or damage the gasket ...

Page 6: ...nce com 6 7 Next pull the brake booster hose free from the driver side intercooler clamp 8 Using a 12mm socket remove the intercooler mounting bolts on either side of the intercooler In addition remove the driver side intercooler bracket It is held on by 2 12mm bolts at the intake manifold ...

Page 7: ...lvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 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 ...

Page 8: ... the sides and carefully wiggle it out of the engine bay Be cautious to not damage the A C line that runs along the fire wall or the intercooler fins 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 ...

Page 9: ...Ph 410 840 3555 www iagperformance com 9 12 Locate the passenger side valve cover breather line 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 ...

Page 10: ...nce 1203 Baltimore Blvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 10 13 Repeat the process on the driver side forward most valve cover breather hose Remove the driver side hose from the engine bay ...

Page 11: ... secure the throttle body to the intake manifold If the throttle body is stuck gently tap around the sides with a rubber mallet to break the throttle body free Do not lose or damage the OEM Throttle body gasket as it is reused 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 ...

Page 12: ...located behind the intake manifold and in front of the turbo by pressing the gray clip in and pulling outwards 17 Remove the PCV valve assembly with the Crankcase Ventilation Sensor from the engine It may come out with the 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 ...

Page 13: ...3555 www iagperformance com 13 18 Using a 19mm wrench unscrew the PCV vacuum nipple and replace it with the NPT plug using a allen socket The plug comes with thread sealant on it Torque the plug to 15 P lb P R ftR Do not over torque as the intake manifold can be damaged ...

Page 14: ...he throttle body to the intake manifold Torque the 4 10mm bolts to 6 P lb P R ftR 20 Locate the OEM drain hose that the PCV assembly was connected to 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 drain hose as shown ...

Page 15: ...rmance 1203 Baltimore Blvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 15 Supplied drain fitting shown left Drain fitting installed into the OEM hose Drain fitting and hose install port location ...

Page 16: ...e hard breather lines that were once attached to intercooler Use a small flat head screw driver pressing the detent in on the zip tie to free it from the hose Next 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 ...

Page 17: ... from the white portion of driver side Crankcase Ventilation Sensor using needle nose pliers Pull outwards from sensor until it is free Then insert the jumper into the driver side Crankcase Ventilation Sensor mini connector harness as shown Tape the connector end with electrical tape to prevent exposure to the elements ...

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

Page 19: ...Westminster MD 21157 Ph 410 840 3555 www iagperformance com 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 ...

Page 20: ...from the white portion of the passenger side Crankcase Ventilation Sensor using needle nose pliers Pull outwards from sensor until it is free Then insert the jumper into the passenger side connector harness as shown Tape the connector end with electrical tape to prevent exposure to the elements and tuck it out of the way ...

Page 21: ...e com 21 25 Locate the PCV assembly with the Crankcase Ventilation Sensor that was removed from the vehicle Remove the White Crankcase Ventilation sensor from the hose 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 ...

Page 22: ...IAG Performance 1203 Baltimore Blvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 22 ...

Page 23: ...or back into its original location on the engine in front of the turbocharger 27 Using a small flat head screw driver unclip and free the 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 ...

Page 24: ...altimore Blvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 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 ...

Page 25: ...he white portion of the passenger side front Crankcase Ventilation Sensor using needle nose pliers Pull outwards from sensor until it is free 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 ...

Page 26: ...unting bracket located on the passenger side strut tower Using a flat head screw driver pry the harness clip outwards and lift up as shown In order to make room for the AOS carefully cut the 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 ...

Page 27: ...IAG Performance 1203 Baltimore Blvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 27 Main Harness wiring Main wiring harness shown after cutting tape ...

Page 28: ...O2 sensor connection on the passenger side strut tower To provide additional wiring slack carefully cut the electrical tape that doubles the wiring harness on itself Refer to pictures 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 ...

Page 29: ...www iagperformance com 29 33 Using your hands 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 If necessary a pry bar and cloth can be used to carefully manipulate the lines ...

Page 30: ...Performance 1203 Baltimore Blvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 30 34 Using a pop clip tool free the wiring harness loom from the passenger side bracket located next to the turbo ...

Page 31: ...03 Baltimore Blvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 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 ...

Page 32: ...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 38 Install the AOS using the two holes on the strut tower shown in the picture Guide the lower coolant hose underneath the main wire harness while installing the AOS Start the upper M6x10mm bolt first then start the lower M6x10mm bolt Once bo...

Page 33: ...203 Baltimore Blvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 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 ...

Page 34: ...il it clips into place 41 Next install the harness relocation bracket into the same location power steering line bracket using the same 10mm bolt Do not completely tighten the bolt yet Adjust the position of the main harness for clearance and fitment Then finish tightening the 10mm bolt Finally press down on the harness and slightly bend the bracket downwards as shown ...

Page 35: ... 1203 Baltimore Blvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 35 42 To minimize coolant loss pinch off the lower coolant hose that connects the turbo to the cylinder head using hose clamping pliers ...

Page 36: ... hose off 44 The IAG AOS upper coolant line will attach to the OEM coolant expansion tank Trim the upper AOS coolant line to the correct length making sure when the line is routed there are not any kinks or obstructions Once cut using pliers pinch and slide the supplied pinch clamp onto the AOS coolant line Then slide hose over the expansion tank port barb and secure the line with the clamp ...

Page 37: ...performance com 37 45 Locate the AOS lower coolant hose The hose should be routed under the main harness and lead to the upper coolant hard pipe on the turbocharger Trim the line to fit onto the upper coolant turbocharger hard pipe Yellow stripe shows routing to turbo coolant line ...

Page 38: ...lvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 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 ...

Page 39: ...EM upper coolant line off the turbocharger hard pipe and quickly swap the lower IAG AOS coolant line in place If done correctly minimal coolant should be lost 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 ...

Page 40: ...te the AOS oil drain line The line will route over the transmission thru the turbo support bracket and finally lead to the port on the plastic drain fitting located on the engine block The hose is supplied long to allow for various turbochargers intercoolers and downpipes Make sure when trimming the length that the hose is free of heat sources and the line is not kinked Once the hose is in place i...

Page 41: ...IAG Performance 1203 Baltimore Blvd Westminster MD 21157 Ph 410 840 3555 www iagperformance com 41 ...

Page 42: ...the 5 8 breather hose and the plastic 90 fitting included with the AOS kit Cut 3 off the breather hose Slide the 3 length of breather hose onto one side of the 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 ...

Page 43: ...nd then slide the 3 breather hose onto the 5 8 port plastic drain fitting located on the top of the engine as shown Next route the other long end of the 5 8 hose under the turbo support bracket and to the AOS lower side port Trim the hose to the correct length and place it on the lower port securing it with a zip tie Make sure to trim the excess zip tie lengths off ...

Page 44: ...te the breather line included in the AOS kit Route one side of the line to the driver side most forward valve cover breather port The line should pass above the 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 ...

Page 45: ...21157 Ph 410 840 3555 www iagperformance com 45 53 Trim the hose to fit the center port on the AOS 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 ...

Page 46: ...840 3555 www iagperformance com 46 54 Using the remaining length of hose route it between the main harness and over top the injector cover bracket Finally slide it onto the passenger side valve cover breather port and secure it with a zip tie and trim the excess off ...

Page 47: ... sure the line is free of kinks or any obstructions Trim the line to fit and secure it with a zip tie trimming off the excess 55 Locate the 1 breather line and route it down the passenger side transmission tunnel starting behind the firewall ac lines Push the line down as far as it can go You may need to get under the car to help guide the hose Attach the upper portion of the line to the upper AOS...

Page 48: ... center exhaust heat shield Make sure the line is free of any kinks then secure the line using an 11 zip tie to the heat shield as shown Snip the excess of the zip tie off 57 Reinstall the intercooler and bypass valve using the OEM hardware and gaskets Reattach the negative battery terminal Make sure to remove any fluid clamping pliers 58 Before proceeding please look over the check list below UCh...

Page 49: ...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 59 After you have reviewed the check list proceed to start the vehicle and check for leaks After the engine has heat cycled you can check the coolant level and replace any coolant that was lost during inst...

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