So...those sensors for the downpipe. How did yours go? Due to the bung locations only one of mine barely reaches (I could probably play it like a guitar string) and the other is about two inches too short. So I'm going to have to lengthen mine.

Anyone else ran into that?

U cant use the clips that hold the wires to the block. Can u take a pic

Sent from my SAMSUNG-SM-N900A using Tapatalk

I'm not using the clips. I tried swapping them since one is longer than the other. But even then I was an inch or so away from the plug.

Huh that's odd. Can u take a pic? Did u ever replace them?

Sent from my SAMSUNG-SM-N900A using Tapatalk

My front O2 sensor was too short but bending the plug bracket down allowed enough space to connect it.

Update, still leaking. Tried a new flange, several gaskets and oil pan sealant. It leaks and only where the turbo and flange meet. I'm removing the turbo and taking a good look at it as something can't be right, this isn't normal and this leak can't be so persistent.

Nope. The car has 1500 miles total. Everything is stock. I took a pic but it's really just me pulling on a wire showing about an inch between the plug and the connector. It's the gray one that won't reach. It's going the shortest path too.

Are you using the new drain thing? My WRX had a precision turbo that leaked no matter what I did. I even tried making a gasket out of copper.

Hopefully that be fancy one will fix it.

Hey yomny how did u mount the intercooler to the crash bar?

Sent from my SAMSUNG-SM-N900A using Tapatalk

I think this is my case lol. I've used everything and anything, even new bolts and washers every time i use a new flange. I've tried three paper gaskets, one new flange without gasket, instead using O-ring and finally oil pan sealant which seals the hell out of anything with oil, apparently it met its nemesis. I'm going to pull the turbo and check for cracks or any visual problems before going back to the original flange and more sealant. Open to suggestions guys, the oil has to be coming from somewhere else but as you see in most pics, every area around the drain port is leak free and clean. :iono:


This is with sealant, freshly installed, let it cure for 24hrs..
http://i29.photobucket.com/albums/c2...417462DF8D.jpg

Here is its 24hrs later after a drive and letting it cool down.. leaking! its not horrible but you could see the oil between the sealant.
http://i29.photobucket.com/albums/c2...49F8BEACAB.jpg

Here's third paper gasket, oem, already saturated with oil, the day after leaked.
http://i29.photobucket.com/albums/c2...A297C597F4.jpg

Here's the O-ring flange, no paper gasket.. leaking.
http://i29.photobucket.com/albums/c2...79A751F4C9.jpg

Here's the new flange, the opening for the drain is almost twice as big as the turbo's opening, meaning anything and everything coming out of that turbo oil drain hole should fall well within, well it doesn't lol.
http://i29.photobucket.com/albums/c2...135B83C885.jpg

I am that point now. Looks like you just notch the crash beam for the ic outlets and then drill a couple holes on the underside of the crash beam.

That's right, mark where the intercooler inlet and outlet would go, take off just what's needed and then drill some holes where the mounting tabs fall on the crash beam. I'm going to post some pics in a bit from my install thread.
@drambo136

Check out this thread, first post you'll see a few good pics of the cutting areas and how to mount. Notice the crash beam on the passenger side has a square hole right in front of the intercooler coupler, I had to cut this open to reach the nut for the bolt secure the intercooler mounting tab, the driver side already has access.
http://www.ft86club.com/forums/showthread.php?t=81623

@yomny - is your bov on the passenger side? The way my outlets were sized my ends up on the driver side...

Those little drips are a pita @yomny. Hate to say it but really common with aftermarket turbo installs. Best thing I can say is don't use paper gaskets and clean the heck out of everything with brake cleaner before putting on any sealant. Then careful with the torque. Overdoing it will have the same effect. It is a low pressure system on the drain side (and coolant side really...) so you don't need torque so much, but a broad clean surface for the gasket maker to stick to and not lift off.