04+ STi, 08-14 WRX Parts Recommendations

These are the parts I recommend.  I recommend them because they work and the companies actually care about the Subaru community.  

• Process West or ETS Top Mount InterCooler (TMIC)
• CobbSF Intake w/ Box
• Cobb, Grimmspeed, Invidia Catted Turbo back exhaust (TBE)
• Cobb or Grimmspeed Electronic Boost Control Solenoid (EBCS)
• Perrin or Killer B Equal Length Header and Up Pipe
• Cobb 1050x Injectors (* 04-06 STi's will need a top feed conversion kit)
• Cobb Flex Fuel
• Cobb Fuel Pressure Sensor
• AEM 340 Fuel Pump
• Cobb Fuel Pressure Regulator Kit (08+ STi only)
• IAG TGV Deletes (only recommended if doing something that requires removing IM)
• Radium Catch Cans or IAG Street AOS
• NGK 1 Step Colder Iridium Plugs (0.028-0.030 gap for pump, 0.026-0.028 gap for e85 or larger turbo pump gas setups)

*  Air pump deletes can cause startup fueling issues due to fueling compensations from undefined tables in the ECU.  Deleting the air pump can/will cause oscillations during coldstart/warmup conditions.  These can be worked around by running the car richer during startup which ultimately isn't great for cats and mufflers.

*  Cobb does not make Stage2 CobbSF+TBE OTS maps because these cars are out of fuel with just an exhaust.  If you want to set the car up properly and be able to take advantage of the additional parts you've added beyond a turbo back exhaust, then you absolutely need ID1050x injectors and AEM340 fuel pump.  And at that point you're an ethanol sensor away from picking up another 40whp....so it makes sense to just get the flex fuel too.

*   I do NOT recommend a catless exhaust unless you get an external wastegate OR Cobb/ID1050x injectors and an AEM340 fuel pump.  Without these mods you chance running out of fuel, leaning out, knock knock boom.

*  I will NOT tune any injectors besides Cobb or Injector Dynamics.  It's an exercise in futility to try and make a car drive well with crappy injectors.

*  If you are running a FMIC, cams, or plan on making 500+ whp then you should plan on going speed density.  Speed density is fueling based off the Manifold Pressure (MAP) sensor vice the Mass Air Flow (MAF) sensor.  The 10-15 feet of extra piping for FMIC's can cause fueling issues on MAF based fueling.  Cams can cause various fueling issues that can only be corrected with speed density.   High hp setups require a large MAF housing which ultimately leads to poor idle and cruise fueling due to the large size of the housing and small size of the MAF sensor.

*  02-07 WRX/STi's need an AEM 3.5 bar MAP sensor or Cobb 4 bar MAP sensor to run more than 20psi.  The stock MAP sensors on these years can only read to 23psi.

*  Fuel Systems

    - Stock Turbo on Flex Fuel

       *  Cobb/ID 1050x injectors + AEM340 Fuel Pump + Cobb Fuel Pressure Regulator

    - FP Blue / 20g / GT30 Size Turbos on Flex Fuel

      *  Cobb/ID 1300x2 injectors + Visconti Tuning Fuel Basket + Walbro525 Fuel Pump + Visconti Tuning Hardwire Kit + Aeromotive or Radium Fuel Pressure Regulator  (this setup could be run with 1050x's, AEM340 and hardwire kit but will max out ~400-425 hp, maybe less depending on how cold it gets where you live.....so if you don't want to run out of fuel....mod accordingly)

   - FP Green /  GT35 Size Turbos on Flex Fuel

      *  Cobb/ID 1700x2 injectors + Radium Dual Hangar Fuel Basket + 2x Walbro450 Fuel Pumps + DW or I-Wire Fuel Pump Hardwire Kits + Aeromotive or Radium Fuel Pressure Regulator + Full Fuel Lines from fuel tank to engine bay

If you plan on tracking your car or do canyon runs all the time with sustained high g turns, then I would highly recommend adding a Surge Tank to the fuel system to keep it under constant pressure and avoid fuel starvation.  Subaru has addressed this issue with the fuel basket on the 08+ cars, but the 2002-2007 WRX's/STi's do not have the basket and will lean out when cornering.  This issue is worse the older the car.

TMIC's should only be used for sub 450 hp cars.  If you want to make power and keep the charge air temps in check, you need a good FMIC.

• Process West, ETS, Cobb, or Perrin FMIC
• CobbSF Intake w/ Box
• Cobb, Grimmspeed, Invidia Catted Turbo back exhaust
• Cobb or Grimmspeed EBCS
• Perrin or Killer B Equal Length Header and Up Pipe
• Grimmspeed Up Pipe w/ Tial 38mm MVS External Wasetgate w/ 12 psi spring
• Cobb 1050x Injectors
• Cobb Flex Fuel
• Cobb Fuel Pressure Sensor
• AEM 340 Fuel Pump
• Cobb Fuel Pressure Regulator Kit (08+ STi only)
• IAG TGV Deletes
• Radium Catch Cans or IAG Comp AOS
•  NGK 1 Step Colder Iridium Plugs (0.028-0.030 gap for pump, 0.026-0.028 gap for e85 or larger turbo pump gas setups) 
• Visconti Tuning Speed Density Kit B w/ IAT sensor and AEM 3.5 Bar MAP sensor

Forced Performance Turbos

- 71HTA Journal Bearing Turbo   (400-425 whp)   

• Flow rating - 51LB per minute
• CW Measurements - 51.2MM Inducer / 68MM Exducer
• TW Measurements - 60.8MM Inducer / 54MM Exducer
• Compressor Housing - 58 MM Stock Appearing Cover
• Turbine Housing - FP 8CM Subaru Turbine Housing

- Blue 73HTZ  (450-475 whp)

• Compressor wheel - 73HTZ
• Flow rating - 57LB per minute
• CW Measurements - 52.6MM Inducer / 73MM Exducer
• TW Measurements - 60.8MM Inducer / 54MM Exducer
• Compressor Housing - 84MM FAP Cover or 58MM Stock Appearing Cover
• Turbine Housing - FP 8CM Subaru Turbine Housing

- Green 76HTZ (475-500 whp) 

• Compressor wheel - 76HTZ
• Flow rating - 61LB per minute
• CW Measurements - 54.8MM Inducer / 76MM Exducer
• TW Measurements - 67.3MM Inducer / 58.8MM Exducer
• Compressor Housing - 60MM Small Inlet or 84MM FAP Cover
• Turbine Housing - FP 8CM Subaru Turbine Housing

- Red 79HTZ (525-550 whp) 

• Compressor wheel - HTZ 79
• Flow rating - 65LB per minute
• CW Measurements - 57.3MM Inducer / 79MM Exducer
• TW Measurements - 67.3MM Inducer / 58.8MM Exducer
• Compressor Housing - 84MM FAP Cover
• Turbine Housing - FP 8CM or 10CM Subaru Turbine Housing

- Black 82HTZ (575-600 whp) 

• Compressor wheel - 82HTZ
• Flow rating - 71LB per minute
• CW Measurements - 59.1MM Inducer / 82MM Exducer
• TW Measurements - 67.3MM Inducer / 58.8MM Exducer
• Compressor Housing - 84MM FAP Cover
• Turbine Housing - FP 8CM or 10CM Subaru Turbine Housing

Full Race EFR7163 Stock Location Turbo Kit

 https://www.full-race.com/store/borg-warner-efr/efr-turbo-kits/subaru-sti-stock-location-efr-internal-wastegate-turbo-kit-2/ 

Full Race Rotated EFR Twinscroll External Wastegate Setups

 https://www.full-race.com/store/borg-warner-efr/efr-turbo-kits/subaru-impreza-wrx-sti-t4-twinscoll-turbo-kit/ 

Quoting power numbers is tricky.  Everything on the car matters.  One big thing people never think about are brakes and wheels/tires.  If you put bigger brake rotors and bigger wheels/tires on your car, you can lose 25-35whp from the extra rotational mass.  I put a 20whp window on the numbers for this reason...and even then you may still fall outside of it.

Stock STi       240-260 tq / 240-260 hp

stock+Tune  280-300 tq / 250-270 hp 

TBE + Tune   290-310 tq / 270-290 hp 

TBE + TMIC + Tune  300-320 tq / 280-300 hp

TBE + TMIC + EL Header + Tune 310-330 tq / 290-310hp

TBE + TMIC + EL Header + ID1050x + AEM320 + Cobb Flex Fuel + Tune 360-380 tq / 340-360 hp