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Intake Manifold: Assembly

WARNING: This page is about a different car, the 2003 Subaru Impreza. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the fuel pipe assembly and pressure regulator, etc. to the intake manifold.
  2. Tighten the bolt which installs the fuel pipes on the intake manifold.
    1. Tightening torque:  5.0 N.m (0.51 kgf-m, 3.7 ft-lb)
    Fig 1: Tightening Bolt Which Installs Fuel Pipes Onto Intake Manifold
    G02621616Courtesy of SUBARU OF AMERICA, INC.
  3. Connect the right side fuel hose to the injector pipe, and tighten the clamp screw.
    Fig 2: Connecting Right Side Fuel Hose To Injector Pipe
    G02621617Courtesy of SUBARU OF AMERICA, INC.
  4. Install the fuel injector pipe.
    Fig 3: Installing Fuel Injector Pipe
    G02621618Courtesy of SUBARU OF AMERICA, INC.
  5. Connect the left side fuel hose to the injector pipe, and tighten the clamp screw.
    Fig 4: Connecting Left Side Fuel Hose To Injector Pipe
    G02621619Courtesy of SUBARU OF AMERICA, INC.
  6. Connect the air assist hoses.
    Fig 5: Connecting Air Assist Hoses
    G02621620Courtesy of SUBARU OF AMERICA, INC.
  7. Install the fuel injectors.
    NOTE: Replace the O-rings with new ones.
    Fig 6: Installing Fuel Injectors
    G02621621Courtesy of SUBARU OF AMERICA, INC.
    NOTE: Do not forget to install the fuel injector securing clip.
    Fig 7: Installing Fuel Injector Securing Clip
    G02621622Courtesy of SUBARU OF AMERICA, INC.
  8. Tighten the bolt which installs the injector pipe on the intake manifold.
    1. Tightening torque:  5.0 N.m (0.51 kgf-m, 3.7 ft-lb)
    Fig 8: Tightening Bolt Which Installs Injector Pipe On Intake Manifold (1 Of 2)
    G02621623Courtesy of SUBARU OF AMERICA, INC.
    1. Tightening torque:  19 N.m (1.9 kgf-m, 13.7 ft-lb)
    Fig 9: Tightening Bolt Which Installs Injector Pipe On Intake Manifold (2 Of 2)
    G02621624Courtesy of SUBARU OF AMERICA, INC.
  9. Tighten the two bolts which install the fuel pipes on the left side of intake manifold
    1. Tightening torque:  5.0 N.m (0.51 kgf.m, 3.7 ft-lb)
    Fig 10: Tightening Bolts Which Install Fuel Pipes On Left Side Of Intake Manifold
    G02621625Courtesy of SUBARU OF AMERICA, INC.
  10. Tighten the bolt which installs the injector pipe on the intake manifold.
    1. Tightening torque:  5.0 N.m (0.51 kgf-m, 3.7 ft-lb)
    Fig 11: Tightening Bolt Which Installs Injector Pipe On Intake Manifold
    G02621626Courtesy of SUBARU OF AMERICA, INC.
  11. Install the purge control solenoid valve.
    1. Tightening torque:  19 N.m (1.9 kgf-m, 13.7 ft-lb)
    Fig 12: Installing Purge Control Solenoid Valve
    G02621627Courtesy of SUBARU OF AMERICA, INC.
  12. Connect the hoses to the purge control solenoid valve.
    CAUTION: Connect the evaporation hose as shown in the figure.
    Fig 13: Connecting Hoses To Purge Control Solenoid Valve
    G02621628Courtesy of SUBARU OF AMERICA, INC.
  13. Install the engine harness onto the intake manifold.
    1. Tightening torque:  16 N.m (1.6 kgf-m, 11.8 ft-lb)
  14. Connect the connectors to the fuel injectors and purge control solenoid valve.
  15. Hold the engine harness by harness band (A) and harness bracket (B).
    Fig 14: Holding Engine Harness By Harness Band & Harness Brackets
    G02621629Courtesy of SUBARU OF AMERICA, INC.
    NOTE: Do not use harness band on harnesses where they are supposed to be protected by the fuel pipe protector.
  16. Install the fuel pipe protector RH.
    1. Tightening torque:  19 N.m (1.9 kgf-m, 13.7 ft-lb)
    Fig 15: Installing Fuel Pipe Protector RH Side
    G02621630Courtesy of SUBARU OF AMERICA, INC.
  17. Install the fuel pipe protector LH.
    1. Tightening torque:  19 N.m (1.9 kgf-m, 13.7 ft-lb)
    Fig 16: Installing Fuel Pipe Protector LH Side
    G02621631Courtesy of SUBARU OF AMERICA, INC.
  18. Connect the pressure regulator vacuum hose to the intake manifold.
    Fig 17: Connecting Pressure Regulator Vacuum Hose To Intake Manifold
    G02621632Courtesy of SUBARU OF AMERICA, INC.
  19. Install the air assist injector solenoid valve to the bracket.
    1. Tightening torque:  6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
    Fig 18: Installing Air Assist Injector Solenoid Valve To Bracket
    G02621677Courtesy of SUBARU OF AMERICA, INC.
  20. Install the throttle body to the intake manifold. See INSTALLATION , Throttle Body.
  21. Install the ignition coil and ignitor assembly.
    Fig 19: Installing Throttle Body To Intake Manifold
    G02621633Courtesy of SUBARU OF AMERICA, INC.
  22. Connect the connector to the ignition coil and ignitor assembly.
  23. Install the engine ground terminal to the intake manifold.
    1. Tightening torque:  19 N.m (1.9 kgf-m, 13.7 ft-lb)
    Fig 20: Installing Engine Ground Terminal To Intake Manifold
    G02621634Courtesy of SUBARU OF AMERICA, INC.
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