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GAU-100x Gauge System Installation Instructions

IMPORTANT! Read these instructions thoroughly before installing or using this
product.

1. Introduction

      Thank you for purchasing a WRXtra Gauge System for your Subaru
   Impreza. Please read these instructions carefully to ensure optimum product
   performance. This product is designed for installation in 2002 or later Subaru
   Imprezas.


2. Contents of package:

   (1) Gauge Pod
   (4) Gauge Pod Screws and Clips
   (1) Main Wiring Harness
   (1) Illumination Wiring Harness
   (1) Red T-Tap
   (1) 3/8” Cable Clamp
   (1) Cable Clamp Screw
   (12) Zip Ties
   (1) Spare Fuse

   If you ordered a boost gauge, your package will also have:

   (1) Silicone Boost Gauge Line
   (2) œ” Hose Clamps
   (1) 3/8” Hose Clamp
   (1) 3/8” Cable Clamp

   If you ordered an oil pressure gauge, your package will also have:

   (1) Sandwich Adaptor w/Sender(s)
   (1) Sandwich Adaptor Threaded Post
3. Tools Required:

   #2 Phillips Screwdriver (Both standard and stubby)
   Slotted Screwdriver or 8mm Nutdriver
   12mm & 15/16” Sockets
   Long (>12”) Socket Extension
   17mm Box Wrench
   7/16” Crow’s Foot Wrench
   Pliers


4. Preparing for Installation

IMPORTANT: Before beginning any work, remove the negative (-) cable from
the battery.

   Interior:

      1. Remove cup holder by opening
         it and removing the 2 Phillips
         screws that attach it. There is a
         tab on the underside that will
         interfere with the stereo
         surround trim, so be careful
         removing it. The cup holder
         should pull straight back and up
         to clear the tab. Set cup holder
         aside.




      2. Remove the stereo surround
         trim by pulling it off, starting
         where the cup holder was
         removed and working your way
         around. There are 4 clips that
         hold it in place. Set trim aside.
3. Remove the vent assembly by
         pulling it off. Disconnect the
         hazard switch plug and set
         assembly aside.




      4. Remove clock by pulling it straight up. It may help to push back on the
         2 clips that hold the front of the clock in the dash. They are directly
         above the vent openings. Disconnect the clock plug and set assembly
         aside.




      5. Remove the 6 Phillips screws
         that secure the stereo. Pull the
         stereo out enough to disconnect
         the antenna, ground, and main
         connector. Set stereo aside.




   Engine Compartment:


If your kit includes an oil pressure and/or temperature gauge, perform the
following steps. If not, skip to step 6.

NOTE: This step can be done at any time before the kit is installed. It may be
more convenient to co-ordinate this step with a scheduled oil change.


      1. Following standard oil changing procedures, drain the crankcase oil
         and remove the filter.
2. Apply a light film of oil to the sandwich adaptor O-ring. Install the
          sandwich adaptor body with the oil pressure sender towards the rear of
          the car. Install the threaded post finger tight.



       3. Position the sandwich adaptor
          so that there is even clearance
          between sender(s) and the
          exhaust, oil pan, etc. Continue
          to tighten the threaded post to
          30 to 40 lbs. ft. using a 1” deep
          socket.




       4. Install a new filter and tighten to
          manufacturer’s specifications.




       5. Reinstall oil drain plug and fill crankcase with the appropriate amount
          of manufacturer recommended oil.

NOTE: While it is not necessary, removing the intercooler allows for easier
access to the firewall area for routing cables. If you choose to remove the
intercooler, follow these steps. If you choose to leave it in place, skip to step 13.



       6. Remove the 3 rubber hoses
          from the intercooler by pulling
          them off the metal tubes.
7. Loosen the hose clamp on the
   intake side of the intercooler-to-
   intake hose.

8. Loosen the hose clamp on the
   turbo side of the turbo-to-
   intercooler hose.




9. Remove the (2) 12 mm bolts
   holding the blowoff valve (BOV)
   to the intercooler and set them
   aside. Leave the BOV hoses
   attached.




10. Remove the (2) 12 mm bolts
   holding the intercooler to the
   mounting brackets and set
   them aside.



11. Standing on the driver’s side of the vehicle, grasp the intercooler
   firmly and move it towards the back of the vehicle to remove the
   intercooler-to-intake hose from the intake, and then towards the drivers
   side of the vehicle to remove the turbo-to-intercooler hose from the
   turbo.

12. Lift the intercooler up and out of the vehicle.

13. Locate and remove the large firewall grommet directly above the
   heater hoses and to the left of the clutch master cylinder.
5. Installation

      1. Locate the end of the wiring harness with the 2 modular plugs.

      2. Feed the 2 plugs through the hole in the firewall. The easiest way to
         do this is to attach a stiff wire (such as a straightened coat hanger) to
         the end of the harness. Insert the other end of the wire through the
         hole, then go inside the passenger’s compartment and pull the wire
         through. If your kit includes a boost gauge, feed the boost hose
         through at this time.

NOTE: You may need to trim the firewall insulation slightly to allow the plugs to
fit.

WARNING: Do not force the harness through. Doing so may damage the
connectors and cause the gauges to not work, or work incorrectly.




      3. Pull the harness into the
         passenger’s compartment until
         the firewall grommet makes
         contact with the firewall.




      4. From the engine compartment, push the grommet into the firewall hole
         until it locks in place.



      5. Run the main harness behind
         the clutch master cylinder.
         Locate the throttle cable as it
         exits the firewall to the right of
         the clutch master cylinder. The
         main harness will follow the
         throttle cable to the battery.
6. Lift the red safety cap from the
   positive terminal on the battery.
   You will see a nut that secures
   several ring terminals to the
   battery clamp. Remove this
   nut.



7. Locate the ring terminal on the main harness. Feed the ring terminal
   into the red safety cap and slip it over the stud with the other ring
   terminals.




8. Secure the nut and reposition
   the red safety cap.




9. If your kit includes an oil
   pressure and/or temperature
   gauge the wiring harness near
   the battery connection will split
   into to sections. Run the
   section of the wiring harness
   that does not go to the battery
   connector between the battery
   and the windshield washer
   reservoir down to the engine
   cross member.
10. Run the wiring harness along
          the top of the cross member lip
          and secure with the metal clips.
          Push the connector(s) onto the
          spade terminal(s) on the
          sender(s). Orange is for oil
          temperature (small sender) and
          brown is for oil pressure (large
          sender)


If your kit includes a boost gauge, follow these steps. If not, skip to step 16.




       11. Locate the hose attached to
          the blow off valve (BOV).




       12. Cut through the BOV hose
          approximately 1” after the bend
          with a hose cutter or sharp
          utility knife.
13. Locate the brass T on the end
   of the long hose supplied in the
   kit and insert the barbed ends
   into the ends of the cut BOV
   hose.




14. Use the 2 large hose clamps to secure both ends of the BOV hose to
   the brass T. Snap the clamps together and use pliers to tighten.




15. Attach the hose as shown in
   the picture using the included
   zip ties. Pull extra hose into
   passenger’s compartment.




16. If you removed the intercooler, reinstall it now by following the steps
   in reverse order.



17. In the passenger’s
   compartment, route the main
   harness and boost hose (if
   applicable) as shown. Fasten
   using the trim screw and cable
   clamp(s).
18. Run the main harness and boost hose (if applicable) into the center
   dash area where the stereo is installed. The boost line continues up to
   the left of the center vents and the main harness continues up to the
   right of the vents.


19. Locate the unused plug on the
   stereo wiring harness. It may
   be taped in place. Plug the 2
   spade connectors of the
   illumination harness into the
   female connectors of the
   unused plug. It does not matter
   which spade connector goes
   where.




20. Run the illumination harness
   parallel to the main harness to
   the right of the center vents. At
   this point the ends of the main
   harness, illumination harness,
   and boost line (if applicable) will
   be accessible where the clock
   was installed.




21. Locate the plug that went to
   the clock. Peel back 1-2” of
   tape from the wires going into
   the plug.
22. Install the red T-Tap on the
   yellow wire with the green
   stripe. Position the wire in the
   slot, fold the T-Tap together,
   and lock using pliers.




23. Attach the adhesive-backed
   mounting base to the top of the
   vent duct as shown.




24. Plug the yellow wire with the
   green stripe on the main
   harness into the T-tap. Secure
   the assembly to the mounting
   base with a zip tie.
25. Reinstall the stereo, making
   sure to connect the modular
   plug, antenna, and ground.
   Attach the ground wire from the
   gauge harness as shown.




26. Reinstall the vents by attaching the hazard switch plug and snapping
   them into position.

27. Reinstall the cup holder.

28. Reinstall the stereo surround by aligning the clips and pressing them
   into place.

29. Install the mounting clips for the gauge pod. The silver clips go in the
   rear holes and the black clips go in the front slots.

30. Position the gauge chassis over the dash. Connect the boost line (if
   applicable) to the barbed fitting on the back of the gauge. Secure with
   the small hose clamp.

31. Connect the illumination, power, and sender plugs. The plugs are all
   unique so they cannot be connected incorrectly.

32. Position the gauge pod chassis in the dash opening and secure it to
   the dash with the mounting screws.


33. Test fit the gauge pod cover.
   It should snap into place with
   the faceplate flush and even
   against the back of the cover
   opening and the gauges tight
   against their cutouts. If
   everything looks good, you are
   done. If not, proceed to step
   29.
34. The faceplate can be adjusted front and back by loosening the 4
          screws that hold the faceplate to the gauge pod chassis and sliding the
          faceplate. The height of the chassis as it sits in the dash opening can
          be adjusted by slightly bending the mounting tabs on the side of the
          chassis. Since every dash is a little different, you may have to make a
          couple adjustments for satisfactory fit.

       35. Double-check all connections to make sure they are secure. Secure
          any wires or hoses with the provided zip ties to prevent them from
          contacting moving parts or interfering with the driver or controls.

       36. Reconnect the ground cable at the battery.

IMPORTANT: When you start your vehicle for the first time, make a careful
inspection of all hoses and fittings. Oil leaking onto a hot turbo or exhaust can
cause fires. If you discover any leaks, immediately shut off the engine and
investigate.

Congratulations. Your gauges are now installed. If your electronic gauges fail to
function, always check the fuse first. A spare fuse is included in the kit. Make
note of where your gauges indicate during normal driving. This will give you a
good baseline to know when something is wrong.

Typical gauge readings:

Oil Pressure (Hot): 25-30 PSI Idle, 80-90 PSI max
Oil Pressure (Cold): 100 PSI or more
Oil Temperature (Hot): 180-210 normal operating range*

* Measured with the sandwich adaptor; oil plug adaptor will read lower.




This document is available online at http://www.wrxtra.com in the Documentation
section.

Document #DOC-1010

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Doc 1010

  • 1. GAU-100x Gauge System Installation Instructions IMPORTANT! Read these instructions thoroughly before installing or using this product. 1. Introduction Thank you for purchasing a WRXtra Gauge System for your Subaru Impreza. Please read these instructions carefully to ensure optimum product performance. This product is designed for installation in 2002 or later Subaru Imprezas. 2. Contents of package: (1) Gauge Pod (4) Gauge Pod Screws and Clips (1) Main Wiring Harness (1) Illumination Wiring Harness (1) Red T-Tap (1) 3/8” Cable Clamp (1) Cable Clamp Screw (12) Zip Ties (1) Spare Fuse If you ordered a boost gauge, your package will also have: (1) Silicone Boost Gauge Line (2) œ” Hose Clamps (1) 3/8” Hose Clamp (1) 3/8” Cable Clamp If you ordered an oil pressure gauge, your package will also have: (1) Sandwich Adaptor w/Sender(s) (1) Sandwich Adaptor Threaded Post
  • 2. 3. Tools Required: #2 Phillips Screwdriver (Both standard and stubby) Slotted Screwdriver or 8mm Nutdriver 12mm & 15/16” Sockets Long (>12”) Socket Extension 17mm Box Wrench 7/16” Crow’s Foot Wrench Pliers 4. Preparing for Installation IMPORTANT: Before beginning any work, remove the negative (-) cable from the battery. Interior: 1. Remove cup holder by opening it and removing the 2 Phillips screws that attach it. There is a tab on the underside that will interfere with the stereo surround trim, so be careful removing it. The cup holder should pull straight back and up to clear the tab. Set cup holder aside. 2. Remove the stereo surround trim by pulling it off, starting where the cup holder was removed and working your way around. There are 4 clips that hold it in place. Set trim aside.
  • 3. 3. Remove the vent assembly by pulling it off. Disconnect the hazard switch plug and set assembly aside. 4. Remove clock by pulling it straight up. It may help to push back on the 2 clips that hold the front of the clock in the dash. They are directly above the vent openings. Disconnect the clock plug and set assembly aside. 5. Remove the 6 Phillips screws that secure the stereo. Pull the stereo out enough to disconnect the antenna, ground, and main connector. Set stereo aside. Engine Compartment: If your kit includes an oil pressure and/or temperature gauge, perform the following steps. If not, skip to step 6. NOTE: This step can be done at any time before the kit is installed. It may be more convenient to co-ordinate this step with a scheduled oil change. 1. Following standard oil changing procedures, drain the crankcase oil and remove the filter.
  • 4. 2. Apply a light film of oil to the sandwich adaptor O-ring. Install the sandwich adaptor body with the oil pressure sender towards the rear of the car. Install the threaded post finger tight. 3. Position the sandwich adaptor so that there is even clearance between sender(s) and the exhaust, oil pan, etc. Continue to tighten the threaded post to 30 to 40 lbs. ft. using a 1” deep socket. 4. Install a new filter and tighten to manufacturer’s specifications. 5. Reinstall oil drain plug and fill crankcase with the appropriate amount of manufacturer recommended oil. NOTE: While it is not necessary, removing the intercooler allows for easier access to the firewall area for routing cables. If you choose to remove the intercooler, follow these steps. If you choose to leave it in place, skip to step 13. 6. Remove the 3 rubber hoses from the intercooler by pulling them off the metal tubes.
  • 5. 7. Loosen the hose clamp on the intake side of the intercooler-to- intake hose. 8. Loosen the hose clamp on the turbo side of the turbo-to- intercooler hose. 9. Remove the (2) 12 mm bolts holding the blowoff valve (BOV) to the intercooler and set them aside. Leave the BOV hoses attached. 10. Remove the (2) 12 mm bolts holding the intercooler to the mounting brackets and set them aside. 11. Standing on the driver’s side of the vehicle, grasp the intercooler firmly and move it towards the back of the vehicle to remove the intercooler-to-intake hose from the intake, and then towards the drivers side of the vehicle to remove the turbo-to-intercooler hose from the turbo. 12. Lift the intercooler up and out of the vehicle. 13. Locate and remove the large firewall grommet directly above the heater hoses and to the left of the clutch master cylinder.
  • 6. 5. Installation 1. Locate the end of the wiring harness with the 2 modular plugs. 2. Feed the 2 plugs through the hole in the firewall. The easiest way to do this is to attach a stiff wire (such as a straightened coat hanger) to the end of the harness. Insert the other end of the wire through the hole, then go inside the passenger’s compartment and pull the wire through. If your kit includes a boost gauge, feed the boost hose through at this time. NOTE: You may need to trim the firewall insulation slightly to allow the plugs to fit. WARNING: Do not force the harness through. Doing so may damage the connectors and cause the gauges to not work, or work incorrectly. 3. Pull the harness into the passenger’s compartment until the firewall grommet makes contact with the firewall. 4. From the engine compartment, push the grommet into the firewall hole until it locks in place. 5. Run the main harness behind the clutch master cylinder. Locate the throttle cable as it exits the firewall to the right of the clutch master cylinder. The main harness will follow the throttle cable to the battery.
  • 7. 6. Lift the red safety cap from the positive terminal on the battery. You will see a nut that secures several ring terminals to the battery clamp. Remove this nut. 7. Locate the ring terminal on the main harness. Feed the ring terminal into the red safety cap and slip it over the stud with the other ring terminals. 8. Secure the nut and reposition the red safety cap. 9. If your kit includes an oil pressure and/or temperature gauge the wiring harness near the battery connection will split into to sections. Run the section of the wiring harness that does not go to the battery connector between the battery and the windshield washer reservoir down to the engine cross member.
  • 8. 10. Run the wiring harness along the top of the cross member lip and secure with the metal clips. Push the connector(s) onto the spade terminal(s) on the sender(s). Orange is for oil temperature (small sender) and brown is for oil pressure (large sender) If your kit includes a boost gauge, follow these steps. If not, skip to step 16. 11. Locate the hose attached to the blow off valve (BOV). 12. Cut through the BOV hose approximately 1” after the bend with a hose cutter or sharp utility knife.
  • 9. 13. Locate the brass T on the end of the long hose supplied in the kit and insert the barbed ends into the ends of the cut BOV hose. 14. Use the 2 large hose clamps to secure both ends of the BOV hose to the brass T. Snap the clamps together and use pliers to tighten. 15. Attach the hose as shown in the picture using the included zip ties. Pull extra hose into passenger’s compartment. 16. If you removed the intercooler, reinstall it now by following the steps in reverse order. 17. In the passenger’s compartment, route the main harness and boost hose (if applicable) as shown. Fasten using the trim screw and cable clamp(s).
  • 10. 18. Run the main harness and boost hose (if applicable) into the center dash area where the stereo is installed. The boost line continues up to the left of the center vents and the main harness continues up to the right of the vents. 19. Locate the unused plug on the stereo wiring harness. It may be taped in place. Plug the 2 spade connectors of the illumination harness into the female connectors of the unused plug. It does not matter which spade connector goes where. 20. Run the illumination harness parallel to the main harness to the right of the center vents. At this point the ends of the main harness, illumination harness, and boost line (if applicable) will be accessible where the clock was installed. 21. Locate the plug that went to the clock. Peel back 1-2” of tape from the wires going into the plug.
  • 11. 22. Install the red T-Tap on the yellow wire with the green stripe. Position the wire in the slot, fold the T-Tap together, and lock using pliers. 23. Attach the adhesive-backed mounting base to the top of the vent duct as shown. 24. Plug the yellow wire with the green stripe on the main harness into the T-tap. Secure the assembly to the mounting base with a zip tie.
  • 12. 25. Reinstall the stereo, making sure to connect the modular plug, antenna, and ground. Attach the ground wire from the gauge harness as shown. 26. Reinstall the vents by attaching the hazard switch plug and snapping them into position. 27. Reinstall the cup holder. 28. Reinstall the stereo surround by aligning the clips and pressing them into place. 29. Install the mounting clips for the gauge pod. The silver clips go in the rear holes and the black clips go in the front slots. 30. Position the gauge chassis over the dash. Connect the boost line (if applicable) to the barbed fitting on the back of the gauge. Secure with the small hose clamp. 31. Connect the illumination, power, and sender plugs. The plugs are all unique so they cannot be connected incorrectly. 32. Position the gauge pod chassis in the dash opening and secure it to the dash with the mounting screws. 33. Test fit the gauge pod cover. It should snap into place with the faceplate flush and even against the back of the cover opening and the gauges tight against their cutouts. If everything looks good, you are done. If not, proceed to step 29.
  • 13. 34. The faceplate can be adjusted front and back by loosening the 4 screws that hold the faceplate to the gauge pod chassis and sliding the faceplate. The height of the chassis as it sits in the dash opening can be adjusted by slightly bending the mounting tabs on the side of the chassis. Since every dash is a little different, you may have to make a couple adjustments for satisfactory fit. 35. Double-check all connections to make sure they are secure. Secure any wires or hoses with the provided zip ties to prevent them from contacting moving parts or interfering with the driver or controls. 36. Reconnect the ground cable at the battery. IMPORTANT: When you start your vehicle for the first time, make a careful inspection of all hoses and fittings. Oil leaking onto a hot turbo or exhaust can cause fires. If you discover any leaks, immediately shut off the engine and investigate. Congratulations. Your gauges are now installed. If your electronic gauges fail to function, always check the fuse first. A spare fuse is included in the kit. Make note of where your gauges indicate during normal driving. This will give you a good baseline to know when something is wrong. Typical gauge readings: Oil Pressure (Hot): 25-30 PSI Idle, 80-90 PSI max Oil Pressure (Cold): 100 PSI or more Oil Temperature (Hot): 180-210 normal operating range* * Measured with the sandwich adaptor; oil plug adaptor will read lower. This document is available online at http://www.wrxtra.com in the Documentation section. Document #DOC-1010