IAG Air / Oil Separator (AOS) For 2002-07 WRX & 2004-07 STi

Part# IAG-ENG-7000
Tools Required: Ratchet, torque wrench, extensions,
needle nose pliers, hose cutter, snips/scissors
Sockets: 10mm, 12mm 13mm
Wrenches: 10mm, 13mm, 19mm 11/16 ”
Hex: 5mm, ¼

Congratulations on the purchase of your Air/Oil Separator

(AOS) and thank you for choosing IAG Performance. This
installation manual is intended to guide you through the
removal of the factory PCV system and the installation of
the IAG AOS. If you already have an aftermarket catch can
or AOS installed, please consult the specific instructions for
your hardware to aid in its removal.

Parts List
Part Name Quantity Notes
Air/Oil Separator 1
Oil Drain Hose Assembly 1 24” Hose Length
Top Coolant Hose Assembly 1 18” Hose Length, Straight Hose Barb, ½” ID
Bottom Coolant Hose Assembly 1 20” Hose Length, 45° Hose Barb, ½” ID
Discharge Hose 1 60” Hose Length, 1” ID
5
Block Breather Hose 1 23” Hose Length, /8” ID
Valve Cover Breather Hose 1 72” Hose Length, ½” ID
5mm ID O-ring 1
7mm ID O-ring 1
Mounting Bracket 1
PCV Replacement Fitting 1
6x12mm Bolt 3
6mm Washers 4
8mm Washer 1
½” High Temp Rubber Cap 1
5
/8” High Temp Rubber Cap 1
4” Zip Tie 3
6” Zip Tie 10
12” Zip Tie 3
¼” NPT Plug 1
3mm “L” Allen Key 1
For 2008+ Installs (Included in packaging)
6mmx17mm Spacer 1 08+ Install Only
8mmx27mm Spacer 1 08+ Install Only
6x35mm Bolt 1 08+ Install Only
8x45mm Volt 1 08+ Install Only
Harness Relocation Bracket 1 08+ Install Only
For 2002-07 Installs (Included in packaging)
6mmx29mm Spacer 1 02-07 Install Only
8mmx25mm Spacer 1 02-07 Install Only
6x45mm Bolt 1 02-07 Install Only
8x50mm Bolt 1 02-07 Install Only

IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com 1
The AOS comes assembled and ready to install. There are 3
o-ring boss (ORB) to AN fittings as well 2 ORB plugs that
are tightened before shipping. If you remove these fittings
please make sure that that they tightened down to ensure
the o-ring is properly seated.

You will find two bags that contain bolts and spacers. One
bag is marked 02-07 and the other is marked 08+. Each bag
contains (1) 6mm bolt and spacer as well as (1) 8mm bolt
and spacer. The 08+hardware bag also contains a harness
relocation bracket. Please use the bag that corresponds to
the year of your vehicle. You can set the other bag aside as
you will not be using it.

Removal - 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. Remove the rubber breather hoses from the metal

crossover pipe. There are two on the passenger side and
one the driver’s side. Some vehicles may use spring
clamps. You should be able to twist and pull the hoses off
once the clamps are removed. If you’d like, you can also
remove the metal crossover pipe by removing the 2 bolts
that hold it to the intercooler. This is optional. The
crossover pipe will not be utilized with the IAG AOS.

IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com 2
4. Using a 12mm socket, remove intercooler mounting
bolts on both sides of the intercooler. There is one on each
side.

5. Using a 12mm socket, remove the two bolts that hold

the blow off valve (BOV) to the intercooler. You can leave
the BOV where it sits. Be careful not to lose the gasket.

6. Using a flat head screw driver, loosen the hose clamp

that is around the turbo discharge silicone coupler.

IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com 3
7. Using a flat head screw driver, loosen the hose clamp
that is around the intercooler outlet silicone coupler.

8. Grab the intercooler by the sides and carefully wiggle it

out of the engine bay. Be cautious to not hit the A/C line
that runs along the fire wall.

9. Using a 10mm socket, remove the 4 bolts that 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.

10. Remove the rubber hose from the PCV nipple under
the throttle body.

IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com 4
11. Using a 19mm wrench, unscrew the PCV nipple and
replace it with the ¼ NPT plug using a ¼” hex. Use thread
sealant or tape on the plug. Torque to 15 lb/ft.

12. Re-install the throttle body to the intake manifold.

Torque bolts to 6 lb/ft.

13. Disconnect the electrical connector from the blow by

sensor in the turbo inlet.

14. Pull PCV fitting from the crank case breather. This is
located underneath the turbo on the passenger side of the
engine block. The stubby rubber hose might come up with
the PCV fitting. This is OK.

IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com 5
15. With the PCV fitting removed from the block, you
should now be able to separate the PCV fitting with the
hose and white blow by sensor attached to it.

16. Take the ½” rubber cap and place it over the barbed
side of the white blow by sensor. Zip tie the cap in place
and then plug the sensor back into turbo inlet and
reconnect the harness to the sensor.

17. Pull the hose that goes from the turbo inlet to the
metal cross over pipe. Be careful not to break the plastic
elbow that sticks out of the turbo inlet. Take the 5/8”
rubber cap and place it over the elbow. Secure the cap
with a zip tie.

**Some models use an additional blow by sensor that

operates in between the crossover pipe and the turbo
inlet. In this case, remove the entire hose assembly and
cap the plastic elbow as described. You will then pull the
flat blade connector out of the blow by sensor and insert it
into the electrical connector. Using electrical tape, cover
the connector and tuck it away.**

IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com 6
18. Remove the forward most valve cover breather hose
on each valve cover. These are the hoses that connect the
valve cover to the metal crossover pipe. Note: There are
two ports next to each other on the valve cover. One port
is larger than the other. You only want to remove the hose
on the smaller port. Do not touch the larger port or hose.

Install – Please read through the entire install instructions before proceeding.
19. 2.0L vehicles that are equipped with cruise control will
need to relocate the cruise control module.

IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com 7
19. Take the supplied PCV replacement fitting from the
hardware bag and insert it into the rubber hose on the
block. The two barbs that make the “Y” should be pointed
up. (Note, if the rubber hose came off when removing the
factory fitting then, you can place the fitting in the hose on
your workbench and then insert the other end of the hose
onto the metal barb that sticks out of the block.)

20. For 06-07 vehicles, use a small pick and disconnect the
wiring harness from the bracket that is attached to the
passenger side strut tower.

21. Using a 12mm socket, remove the bolt that holds the
brake line bracket to the passenger strut tower.

For 06-07 vehicles, use a 10mm socket to remove the two

bolts that hold the harness bracket to the strut tower.
Push the harness down and ziptie it to the brake line. You
can set the bracket aside as you will not re-use it.

IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com 8
22. You will have now have 3 exposed holes in the strut
tower. The top two of these holes will be used to mount
the AOS. These holes have nuts that are welded on the
other side of the strut tower. These nuts can become
clogged with rust and debris over time. Take the long 6mm
and 8mm bolts from the bag marked 02-07 and run the
bolts through the hole approximately 1” deep to remove
any foreign media.

You will need a 10mm socket for the 6mm bolt and a
13mm socket for the 8mm bolt. Remove the bolts. (Note:
if the bolts will not thread through the nut, then the nuts
may be severely rusted. In this case, we recommend
running a chaser tap through the nut.)

23. Assemble the flat bracket, bolts, washers, spacers and

o-rings as shown. Orient the spacer so the side with the
groove is facing away from the bracket. The smaller o-ring
is used on the 6mm bolt and the larger o-ring is used on
the 8mm bolt. Slide the o-ring down into the groove. The
o-ring’s only purpose is to prevent the spacer from falling
off of the bolt during installation or removal. The 02-07
WRX/STI uses the bottom 8mm hole on the bracket as
shown.

IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com 9
24. Attach the bracket to the AOS using the 6mm bolts and
washers as shown. Align the bottom hole on the bracket
with the 3rd hole from the bottom on the AOS.

(Note: if you have a rotated turbo or an aftermarket hood,

you will want to install the bracket assembly to the car first
and hold the AOS up to the bracket to see what holes on
the back of AOS that you will need to use.)

25. The AOS and bracket assembly should now be

tightened together. Place the AOS in the engine bay and
run thread the bolts by hand (Note: These are the holes
you previously cleaned out). Using a 10mm and 13mm
wrench, tighten both bolts. Depending on the type of
wrench you use, you may need to use the open end to
tighten the 6mm bolt.

26. Install the oil drain hose by screwing the straight AN

fitting to the bottom port on the AOS. See picture. Run the
open end of the oil drain line to the side port on the Y-
fitting that is in the block. The supplied hose is left long to
accommodate for different mounting configuration. Trim
the hose to the appropriate length and slide the hose over
the side barb on the Y-fitting. Zip tie the connection.
Tighten the AN fitting with an 11/16” wrench.

IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com 10
27. Install the block breather hose by sliding one end of
the oil breather hose to the top barb on the PCV
replacement fitting (this is the top barb on the “Y”). Zip tie
the connection. Run the other end to the top hose barb on
the side of the AOS as shown. Trim the hose to length. Zip
tie the connection.

IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com 11
IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com 12
28. Install the valve cover breather hoses by sliding the oil
breather hose to the driver’s side valve cover port and
running the hose to the middle port on the side of the
AOS. Keep the hose distance to a minimum as you will use
the remaining hose to run the passenger side valve cover
port. Trim the driver’s side hose to length and zip tie both
connections. With the remaining hose, do the same for the
passenger’s side valve cover and zip tie both connections.

IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com 13
Coolant – Please follow these instructions carefully as
you will be opening up the coolant system. You want to
minimize the coolant loss to avoid creating an air pocked
in the coolant system. You are replacing the coolant hose
that runs from the top of the coolant expansion tank to
the top turbo coolant pipe.

29. Install the bottom coolant line by screwing the 45°

fitting into the side port on the bottom of the AOS. You
can leave the fitting loose to aid in orientation. Run the
open end of the hose up to the top of the coolant
expansion tank. Place the hose side by side with the
factory hose to measure the correct length and then trim
the hose to length. Tighten the AN fitting on the bottom of
the AOS with an 11/16” wrench.

IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com 14
30. Locate the factory lower turbo coolant hose and pinch
the hose in the middle so coolant can no longer pass
through the hose. Depending on the type of pinch clamp
you have, you might find it helpful to pull back the heat
shield sheath around the hose. Loosen the tension on the
spring clamp that is on the upper factory turbo coolant
hose. Proceed to pull the factory hose off of the coolant
expansion tank. Quickly, slide the existing spring clamp
over the exposed end of the AOS hose and then push the
hose over the exposed barb on the expansion tank and
tighten with the spring clamp.

IAG Performance | 1203 Baltimore Blvd. Westminster, MD 21157 | Ph: 410-840-3555 | www.iagperformance.com 15
31. Install the top coolant hose by screwing the straight AN
fitting to the top port on the AOS. Tighten the fitting with
an 11/16” wrench. Run the open end of the hose next to the
factory hose on the turbo coolant pipe. Place the hose side
by side with the factory hose to measure the correct
length and then trim the hose to length. Loosen the
tension on the spring clamp that is on the factory hose.
Proceed to pull the factory hose off of the turbo coolant
pipe. Quickly, slide the existing spring clamp over the
exposed end of the AOS hose and then push the hose over
turbo coolant pipe and tighten with the spring clamp.

**If this procedure is done quickly and correctly, the

amount of coolant lost should be minimal and will not
require burping the system**

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32. Install the 1” AOS breather hose by sliding one end of
the hose over the top port. (Note, if you need to change
the orientation of the top port, you can use the supplied
3mm allen wrench to remove the top bolt and turn the top
port in the direction you desire. Once the top is oriented,
re-install the bolt you removed and tighten.) Secure the
hose to the top breather port with a 12” zip tie.

33. Run the 1” hose down the transmission tunnel and

secure with the remaining 12” zip ties. Make sure that the
hose is not bent or kinked as this will cause operating
issues. Keep the hose at least a few inches from your
downpipe as you route it down. We do not recommend
trimming this hose. The farther back the hose discharges,
the less likely you are to smell oil vapor inside the vehicle.

34. Re-install the intercooler hose connections starting

with the turbo discharge coupler. Again, be careful of the
firewall A/C line.

**The bolts that hold the intercooler to the mounting

bracket and the bolts that hold the BOV to the intercooler
are the same diameter but slightly different lengths. The
shorter bolts are used for the BOV. If you attempt to install
the longer bolts, you may damage your intercooler**

40. Re-install the BOV with gasket. Once the BOV is secure
to the intercooler, tighten the hose clamps around the

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silicone coupler. Re-install the mounting bolts on the side
of the intercooler.

35. Before proceeding, please look over the check list

below:

Check Over List

Are all AN fittings tight (two coolant fittings and one oil
drain)?

Are the factory hose clamps re-installed on the turbo

coolant pipe and the expansion tank?

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:

• ½” 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

36. 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 installation.

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