Subaru Legacy Twin Turbo Intercooler Removal and Fitment How-to

My first tutorial vid, showing the only REAL method to dealing with TT intercoolers!
Today's car is a manual 1998 BH5A GTB. This method however is identical on all TT Legacy's. There are some minor changes in vac layout between versions, but all verisons have the three intercooler vac lins grouped on plug 1.
I have a thread going on SL-i.net covering differences between twin turbo models in great detail, it's a work in progress
sl-i.net/FORUM...
If you want any other vids on twin turbo's, JDM stuff, or just in general don't hesitate to ask. Next vid I may film will be doing rear lateral arms on a 1995 Version 2 WRX.
Also have yet to buy a mic, and I live under the flight path for Queenstown Airport, so audio in this one is terrible. Sorry, but we all start somewhere.

[@og_halo5111]

1:53 I didn't know you can remove the fork shaped clamp and take the plug with the vacuum hoes on it, thank you for sharing it's gonna make my job a lot easier

[@DriveFresh94]

Love the video! I'm from the states and bought a '98 GT-B that's being stored in Canada until it's legal. Definitely looking forward to more content so I can get a jumpstart on how to work on it properly. Keep it up!

[@Boostedbeater]

Isnt that legal this year?!

[@DriveFresh94]

@seth larson Yep! Unfortunately I sold it but I have another one lined up to be shipped soon.

[@faustini69]

Did this today. I found using a strap on the secondary pipe elbow makes fitting it super easy. Pull the elbow towards the rhd side and it pops onto the turbo

[@CapnLubeHandles]

I'm years late, but i just had a legacy gtb imported and holy shit this video is my Bible

[@DaBlueMonster]

Awesome!! Now I can get to and replace my BH5 TT PCV! 💯👍🏻👍🏻👍🏻

[@IZichard]

Great video Reuben! I always struggle with these, my GC8 is so easy by comparison. We've got the silly hi vis orange gloves at work too since QT ran out of the nice black ones haha.

[@BO0O0O0O0O0O01]

I need this quality of video to walk me through replacing the twin turbo inlet hose, I got a silicone one to put into my 02 rev D. I'm scared of messing up or forgetting something this definitely helped my confidence for removing the intercooler though!

[@SubieSpecs]

If ya can wait a month or two, I’ve filmed a vid on how to remove the manifold on an ‘02 Rev-D. It’s a few spots down the video queue though.

[@BO0O0O0O0O0O01]

@SubieSpecs I unfortunately can't wait, I'm going to pull off the intercooler today and evaluate my next step from there. I've already removed intake and airbox. I got to get it up and running quickly now that I have a new inlet. I don't have a garage, and we already have snow in the forecast for next week :/ I will be sure to watch your video when you do post it. Then I can see what I did wrong, aha!

[@BO0O0O0O0O0O01]

@SubieSpecs I also found a post that I'm pretty sure you wrote in regards to these cars, has vacuum diagrams for each revision, and kind of what not to do. It's very well written and I'm sure to reference it.

[@SubieSpecs]

Yup, on SL-i.net, it should help. One thing you should do is order the crank case breather stand off, and F-pipe tee piece, for the PCV system. These will brake. Also be mindful of, and don’t snap the nipples off your evap solenoid. Those are the big two common mishaps.

[@BO0O0O0O0O0O01]

@SubieSpecs I'll see if the shop I use to let deal with the car can order those parts for me! I'll need to buy a new intake manifold gasket anyhow! Thanks for the heads up, I was told that it was pretty inevitable that some pvc was going to break once I got in there. I wasn't sure what, though. Any idea what fittings I'll need to get for the new silicone inlet? I was told by someone that the factory ones couldn't be reused as they're formed as one with the oem inlet.

[@nuwankm4433]

Love the video. Thanks and this was very helpful for me to remove the intercooler to clean up the dirt stuff. (y)

[@faustini69]

Awesome video. Such a horrible design with these hoses! I've got an 01 rev d that's having issues. Pulling about 7psi on both primary and secondary. Secondary kicks in at 4500rpm Cleaned the the black box solonoids. Cleaned the Afm. Changed the alternator Fitted hiflow down cat. Removed center cat Subi Mechanic say the ecu is pulling timing and running lean. Guessing it's in boost limp?

[@PichusTrianun]

Thank you , this help me a lot.

[@tiaelliott6651]

Wish I found this video before ripping tf out my intake hose……😅

[@cjnewson88]

Just what I was looking for. Cheers! I got a 98 GT-B looks same as yours. Any chance you could upload a video how to get to the spark plugs? The Battery/Washer bottle side looks easy enough, but the side with the secondary turbo looks restricted as heck.....

[@SubieSpecs]

Pretty easy actually, you just take the whole air box out, opens things right up. Getting exactly the right length extension between the plug socked and ratchet is key

[@cjnewson88]

@@SubieSpecs alright I'll give it a crack. What extension length would you recommend?

[@SubieSpecs]

3”/10cm. It’s perfect. Use 3/8 tools too, not 1/2”, 1/2 is too big and clunky to fit in the tight spaces.

[@-smokintrees-8590]

Have a 2000 legacy gt and mann did this help. Ran into a little bit of an issue reinstalling the intercooler and ended up mangling the plastic oem hoses from the turbos.. thats okay though, i just bought a 1999 legacy gtb e tune as a parts car, and i plan on swapping the intercoolers and tubing (next time one of the many coolant lines spring a pinhole leak and i have to tear everything apart) Lol atleast i am a little wiser this time around. It is currently winter, and i wont be driving the car for a few more weeks, any info on weither an aftermarket silicone hose in place of said hoses is a good idea? Where if anywhere could i find a pair? I can barely find anything about these cars specifically on the web. :( Any info helps, thanks and have a great day!

[@justcloak3223]

Yeah these cars are rare af to find parts, you'll just have to diy with some hoses and do some measurements. I had a boost leak in primary hose and intercooler itself so i just replaced whole thing for like 350$ But it works awesome now so it was worth

[@dmotoguy5640]

Hi Reuben do you know what each valve does under the intercooler, when i got my Rev D tuned he said there was something going on with the secondary turbo so he couldnt up the boost or anything as it was unsafe so just wondering could this valve be my problem. could i just check with movement witha vaccum guage?

[@SubieSpecs]

The intercooler valve is purely to block off the secondary whilst you’re on primary turbo. It’s a simple on or off valve once, secondary boost matches primary, it snaps open (I think it’s decided by load and RPM, but the differential pressure sensor is also used)(the differential pressure sensor is essentially reading boost pressure either side of that valve.) Check out my thread here: sl-i.net/FORUM/showthread.php?20165-So-you-ve-bought-youself-a-JDM-twin-turbo-eh

[@danielmcloughlin820]

@@SubieSpecs ok thank you there was a sleeve broken inside my secondary downpipe so im hoping that was actually causing the issue. The car has been running great since the tune but i do have to go back as he didnt get to finish it 100 percent and be happy so i would like to sort any issues. Yes thanks i will have a look, recently a new member of SLI so thats actually how i came across this video. Looking forward to going through all the threads and learning new things about the legacy and ej swaps.

[@ashwheeler7200]

Hey mate awesome vid I have a 96 gtb bg5 ej20r I was wondering about cleaning the iac but this motor looks diff to all the ones I have seen done on KZbin could you help locate

[@SubieSpecs]

It’s the little dude right next to the throttle body, with that air hose going to it. Easiest way to clean will be taking off said air hose and drowning it in seafoam/Subaru upper engine cleaner. To take it off you’ll want 3 parts hand to replace, if you wanna do it nice and proper. 22657AA000 - 1-way valve 22660AA000 - large locator seal 22659AA060 - gasket Still available from Subaru, but who knows for how much longer.

[@ashwheeler7200]

@@SubieSpecs awesome mate thank you very much

[@rileypaterson7117]

Hey bro can we get another education video? Ahah I've just bought a 96 rhd wagon gt

[@SubieSpecs]

What do yah need to know?

[@rileypaterson7117]

@@SubieSpecs well this video was very helpful tomorrow im installing oem replacement pipes for the intercooler. Not sure yet just anything about these cars I would definitely tune in!

[@animalhouse4222]

@@rileypaterson7117 hey bro haha I am the same I just bought a 96 gt wagon twin turbo but it's really hesitant down low so am currently cleaning everything any tips?

[@rileypaterson7117]

@@animalhouse4222 turbo lag bruh 🤣 jk id have to look in person

[@animalhouse4222]

@@rileypaterson7117 yeah lol goes fine sometimes then other times like no turbos at all maybe a leak somewhere going to have a good look tomorrow

[@kodibrown15]

Is it ok to block off pcv hose that goes to cold air intake. and only run the hose going to underneath the throttle,

[@SubieSpecs]

That would likely result in plumes of oil smoke out your exhaust every time you hit boost.

[@JR-kl3cp]

Got a question. I've got an 01 legacy gtb e tune 2. Does the usdm 02-03 wrx impreza share the same pcv valve/assembly for my jdm model ?

[@SubieSpecs]

11810AA000

[@MikeSerafin]

Thank you, not OP but I came here to inspect, clean or replace my pcv valve, so this helps.

[@ajwr9413]

Hey mate I have a ej20r and it's just started bucking stalling and now it just dies when driving then starts back up at around 1000 rpm.....there is a weird pulsing coming from the fuel line after the fuel filter to the engine 😳 check light comes on then off im not to sure what is going on any idea's

[@SubieSpecs]

Sounds like a more serious mechanical issue, less like a twin turbo issue. I’d be checking all the things that you’d check should this happen to any car. Fuel delivery, intake obstructions/leaks, wiring, grounding etc.

[@ajwr9413]

@@SubieSpecs awesome thanks mate

[@ajwr9413]

@@SubieSpecs hey mate just thought I would update u on what the problem was....the mass airflow sensor had been unscrewed by the previous owner and had broken all three little metal connectors that were soldered on and didn't fix it just wedged it back in!!!!!!! And then o2 sensor was only halfway screwed in😬all fixed for free once I had found the problems now it runs perfect

[@sleedog11]

I can not for the life of my. Get the primary hose back. On even using an silicone hose that's softer

[@SubieSpecs]

Yeah they can be very very argumentative. The trick is to never force it, if it needs to be forced hard, it’s not lined up properly, and that can damage the form of the hose, making it harder for you in future. I may have not made it clear in the video, but the order in which I put the hoses on is very very deliberate, you gotta start with the secondary, then throttle, and primary last. If you do primary first, the secondary doesn’t go on, for example. Primary is theft one btw, passenger side. On your next attempt, ensure the secondary and throttle body are seated properly. The give the primary an ol reach around and make sure that the hose is sitting right, not off to the side slightly. Also make sure the clamp is lose enough, maybe loosen it some more for good measure. And did you grease the hose?

[@adamkelly1492]

@@SubieSpecs thank you for your video, I shall use it to try and change my vf20 primary turbo

[@mamukafadarashvili9971]

I 2 Torbo vacuums are not correct

[@SubieSpecs]

Elaborate

[@rileypaterson7117]

Have you been on regular car reviews

[@SubieSpecs]

Sure was.

[@rileypaterson7117]

@@SubieSpecs thats awesome 👌

[@rileypaterson7117]

Hey I just bought 2 larger turbos vf31 vf32 and I plan to instal them and get a tune have you heard of this being done they are turbos from a 3rd gen legacy being put onto a 96 gtb second gen

[@SubieSpecs]

Yup, was pretty common back in the day. Going on an A-Rev, or GTB? No point in putting them on a GTB, difference in size is negligible. A-rev’s though will see a good upgrade with this. A-revs also have a much more conservative tune, so no need to worry bout that. Just run good fuel, 98 Ron octane or better if you’re concerned.

[@rileypaterson7117]

@@SubieSpecs altight good info its a gtb with ej20R

[@emmanuelmsacky9279]

It's okay to lose power