324600 - VA WRX Flex Fuel Kit Installation Instructions [Discontinued] - Customer Support Center

324600 – COBB DIT Flex Fuel Kit
Subaru WRX 2015-2020

Congratulations on your purchase of the COBB Tuning Flex Fuel kit! The following instructions will assist you through the installation process. Please read them BEFORE beginning the install to familiarize yourself with the steps and tools needed. If you feel you cannot properly perform this installation, we HIGHLY recommend you take the vehicle to a qualified and experienced automotive technician.
 

IMPORTANT! Installing this kit will require custom tuning or utilizing an appropriate Stage Power Package map if you have a matching mechanical configuration. Please consult with COBB or an authorized ProTuner in your area.

Part List

• 1 x Flex Fuel Module
• 1 x Flex Fuel Sensor
• 1 x Long Assembled Fuel Line 
• 1 x Short Assembled Fuel Line 
• 1 x Mounting Bolt
• 3 x Small Zip Ties
• 2 x Medium Zip Ties
  (Some kits may also have a hose clamp - it is not needed on DIT WRX vehicles)

Tools Needed

• 7mm Nut Driver
• Flat Head Screwdriver
• Trim clip removal tool (optional)
• 10mm Wrench
• 12mm Wrench
• 10mm Socket
• 12mm Socket
• Ratchet
• Pliers
• Safety Glasses
• Rags
• Silicone Spray or Similar

Important! Before removing your fuel line, make sure to discharge existing fuel pressure from the system. Failure to do so can result in fire, property damage, and/or death! 

Initial Preparation and Removal of Existing Fuel Lines

1. Inspect the new components included with the COBB kit. If anything appears out of place, please contact COBB immediately and do not proceed with the installation.
2. Make sure the engine is off and completely cool. Discharge the existing fuel pressure from the system. Consult the factory service manual for OEM methods. One potential method is to disable the fuel pump by pulling the fuse on the driver's side of the engine bay (consult the underside of the lid for correct fuse location), then attempt to start the vehicle. The vehicle will likely run for a brief moment and stall. Fuel pressure is reduced by this method, but some pressure may remain in the system.
3. Cranking the engine to remove fuel pressure is slightly different for a DIT car. First, remove the fuel pump fuse which is in an identical location and amperage to the previous generation (pictured)
   
4. On your AccessPort, set up a monitor for Fuel Pressure, similar to the following picture. You will notice that on a recently driven car, fuel pressure will be several thousand PSI
   
5. Start the car with the fuel pump fuse removed. If it refuses to start (for instance, if you have failed to crank the engine fully), you may need to remove the fuse after the engine has started. The car will likely run for a surprising amount of time without the low pressure pump. Wait for fuel pressure to drop into the tens rather than thousands, which is about when it starts to sputter, and shut off the car.
   
6. Raise and suitably support the vehicle. Never work on a vehicle supported by a jack alone.
7. Disconnect the vehicle's negative battery terminal, then positive battery terminal with a 10mm wrench or socket. Ensure no sources of spark or flame are present. Remove battery from vehicle.
8. Prepare spill catch rags in case of fuel spills during line removal.
9. Remove the primary (only) fuel line from the vehicle by pressing in on the blue tab and pulling the line off. 
   
10. Remove the leftover plastic tabs from the fuel lines, as they will not be needed with the new lines.

Installation of COBB Flex Fuel Kit Hoses

The COBB Flex Fuel Sensor installs in the new feed line between the manifold connector and the firewall.

Installation of COBB Flex Fuel Module

The COBB Flex Fuel Module is designed to be bolted to the inter-cooler support bracket and plugged into the COBB Ethanol Sensor, in-line with the factory Rear O2 sensor and Tumble Generator Valve (TGV).

The Rear O2 connector obtains 12V power, and does not alter the O2 sensor signal going to the ECU. The TGV connection allows the motor signals to pass through for those still using the factory TGV's, however the feedback normally used to check TGV position is used to transmit Ethanol content data to the ECU (Engine Control Unit).

Mounting location may vary by customer/ installer preference, however it is recommended to seal any un-used connections from water intrusion, ideally by using the proper connector mate and using plugs to seal the mating connector.

1. Bolt the Flex Fuel module to the inter-cooler support bracket using the included bolt. Straighten the cables so that they aren't crossed over each other.
2. Plug in the TGV connector in-line to the TGV (as shown below)

   
   

3. Pass the Flex Fuel Connector through the factory hoses and wiring harnesses and plug it into the Ethanol sensor. Ensure there is no strain on the connector, wiring, or the module.
4. From the bottom of the vehicle, remove the black plastic splash/ aero cover using a 12mm socket for the two bolts and a screwdriver/ trim clip removal tool for the clips around the panel.

   

5. Route the (4-pin) Rear O2 Connector to the front of the car, down toward the exhaust.
   
   
6. Connect the Rear O2 Connector between the factory O2 sensor harness and the O2 Sensor connector. Using the included zip-ties, secure the connectors as far away from the exhaust pipe as possible but without inducing strain on the harnesses.

   

7. The O2 connector harness has extra length to work on a variety of vehicle configurations. Using the included zip-ties, secure the harness to the existing main engine harness toward the front of the vehicle. Ensure that the harness will not make contact with moving parts and has sufficient slack between the engine and lines as well as lines and harness so that there is no strain as the engine moves.

Final Assembly

1. Re-install the underbody panel and lower vehicle safely.
2. Re-install the battery, ensuring that it does NOT make contact with the new fuel hose, as the sensor bracket is designed to press against the fuse box, but NOT make contact with the battery.
3. Reconnect the positive terminal, and cover with the factory guard to reduce the risk of short circuiting the battery. In case you missed the step above, make sure there is NO exposed fuel or rags near the car. Fumes can easily be ignited when connecting the battery.
4. Reconnect the negative battery terminal and prime the fuel system by cycling the key between the "OFF" and "RUN" positions at 3-second intervals. 4 or 5 cycles will be adequate to re-pressurize the low-pressure system. CAREFULLY INSPECT FOR LEAKS AND IMMEDIATELY CORRECT IF ANY ARE FOUND!
5. Prime (Turn the key but do not start the engine until the fuel pump stops), then start the vehicle and again inspect for any leaking or abnormalities. Halt immediately if any fuel leaks or other issues are found!
6. Installation of the Cobb Flex Fuel kit is now complete! We recommend inspecting for any signs of leaking or component deterioration periodically for safety and performance purposes. Enjoy your new COBB Flex Fuel Kit!

Calibration Data

Ethanol Sensor Input Selection = TGV Left

Sensor calibration:

0.5 V = 0% Ethanol

4.5 V = 100% Ethanol