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Home >> Subaru >> 2002 >> Forester Base >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection (Fuel Systems) >> Intake Manifold >> Assembly
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Assembly

  1. Install fuel pipe assembly and pressure regulator, etc. to intake manifold.
  2. Tighten bolt which installs fuel pipes on intake manifold.

    Tightening torque:  5.0 N.m (0.51 kgf-m, 3.7 ft-lb)

    Fig 1: Installing Fuel Pipes
    G02861815Courtesy of SUBARU OF AMERICA, INC.
  3. Connect right side fuel hose to injector pipe, and tighten clamp screw.
    Fig 2: Connecting Right Side Fuel Hose
    G02861816Courtesy of SUBARU OF AMERICA, INC.
  4. Install fuel injector pipe.
    Fig 3: Installing Fuel Injector Pipe
    G02861817Courtesy of SUBARU OF AMERICA, INC.
  5. Connect left side fuel hose to injector pipe, and tighten clamp screw.
    Fig 4: Connecting Left Side Fuel Hose
    G02861818Courtesy of SUBARU OF AMERICA, INC.
  6. Connect air assist hoses.
    Fig 5: Connecting Air Assist Hoses
    G02861819Courtesy of SUBARU OF AMERICA, INC.
  7. Install fuel injectors.
    NOTE: Always use new O-rings.
    Fig 6: Installing Fuel Injectors
    G02861820Courtesy of SUBARU OF AMERICA, INC.
    NOTE: Do not forget to install the fuel injector securing clip.
    Fig 7: Installing Fuel Injector Securing Clip
    G02861821Courtesy of SUBARU OF AMERICA, INC.
  8. Tighten bolt which installs injector pipe on intake manifold.

    Tightening torque:  5.0 N.m (0.51 kgf-m, 3.7 ft-lb)

    Fig 8: Installing Injector Pipe On Intake Manifold
    G02861822Courtesy of SUBARU OF AMERICA, INC.
  9. Tighten two bolts which install fuel pipes on the left side of intake manifold.

    Tightening torque:  5.0 N.m (0.51 kgf-m, 3.7 ft-lb)

    Fig 9: Installing Fuel Pipes On Left Side Of Intake Manifold
    G02861823Courtesy of SUBARU OF AMERICA, INC.
  10. Tighten bolt which installs injector pipe on intake manifold.

    Tightening torque:  5.0 N.m (0.51 kgf-m, 3.7 ft-lb)

    Fig 10: Installing Injector Pipe On Intake Manifold
    G02861824Courtesy of SUBARU OF AMERICA, INC.
  11. Install purge control solenoid valve.

    Tightening torque:  16 N.m (1.6 kgf-m, 12 ft-lb)

    Fig 11: Installing Purge Control Solenoid Valve
    G02861825Courtesy of SUBARU OF AMERICA, INC.
  12. Connect hoses to purge control solenoid valve.
    CAUTION: Carefully connect the evaporation hoses.
    Fig 12: Connecting Hoses To Purge Control Solenoid Valve
    G02861826Courtesy of SUBARU OF AMERICA, INC.
  13. Install engine harness onto intake manifold.
  14. Connect connectors to fuel injectors and purge control solenoid valve.
  15. Hold engine harness by harness band (*).
    Fig 13: Holding Engine Harness By Harness Band
    G02861827Courtesy of SUBARU OF AMERICA, INC.
  16. Connect pressure regulator vacuum hose to intake manifold.
    Fig 14: Connecting Pressure Regulator Vacuum Hose
    G02861828Courtesy of SUBARU OF AMERICA, INC.
  17. Install air assist injector solenoid valve to bracket.

    Tightening torque:  5.0 N.m (0.51 kgf-m, 3.7 ft-lb)

    Fig 15: Installing Air Assist Injector Solenoid Valve
    G02861829Courtesy of SUBARU OF AMERICA, INC.
  18. Connect air by-pass hoses to air assist solenoid valve.
    Fig 16: Installing Air By-Pass Hoses To Air Assist Solenoid Valve
    G02861830Courtesy of SUBARU OF AMERICA, INC.
  19. Connect connector to air assist solenoid valve.
  20. Install throttle body to intake manifold.
    NOTE: Replace gasket with a new one.

    Tightening torque:  22 N.m (2.2 kgf-m, 15.9 ft-lb)

    Fig 17: Installing Throttle Body To Intake Manifold
    G02861831Courtesy of SUBARU OF AMERICA, INC.
  21. Connect connector to throttle position sensor and idle air control solenoid valve.
    Fig 18: Connecting Connector To Throttle Position Sensor And Idle Air Control Solenoid Valve
    G02861832Courtesy of SUBARU OF AMERICA, INC.
  22. Connect air by-pass hose to throttle body.
    Fig 19: Connecting Air By-Pass Hose To Throttle Body
    G02861833Courtesy of SUBARU OF AMERICA, INC.
  23. Install intake air temperature and pressure sensor.

    Tightening torque:  3.4 N-m (0.35 kgf-m, 2.5 ft-lb)

    Fig 20: Installing Intake Air Temperature And Pressure Sensor
    G02861834Courtesy of SUBARU OF AMERICA, INC.
    NOTE: Replace O-ring with a new one.
    Fig 21: Replacing O-Ring
    G02861835Courtesy of SUBARU OF AMERICA, INC.
  24. Connect connector to intake air temperature and pressure sensor.
  25. Install ignition coil and ignitor assembly.
    Fig 22: Installing Ignition Coil And Ignitor Assembly
    G02861836Courtesy of SUBARU OF AMERICA, INC.
  26. Connect connector to ignition coil and ignitor assembly.
  27. Install engine ground terminal to intake manifold.

    Tightening torque:  19 N.m (1.9 kgf-m, 13.7 ft-lb)

    Fig 23: Installing Engine Ground Terminal To Intake Manifold
    G02861837Courtesy of SUBARU OF AMERICA, INC.