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Home >> Subaru >> 2003 >> Baja Standard >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection (Fuel Systems, H4SO) >> Intake Manifold >> Assembly
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Intake Manifold: Assembly

  1. Install fuel pipe assembly and pressure regulator, etc. to intake manifold.
  2. Tighten bolt which installs fuel pipes on intake manifold.
    1. Tightening torque:  4.9 N.m (0.5 kgf-m, 3.6 ft-lb)
      Fig 1: Installing Fuel Pipes Bolt
      G02874853Courtesy of SUBARU OF AMERICA, INC.
  3. Connect right side fuel hose to injector pipe, and tighten clamp screw.
    Fig 2: Tightening Clamp Screw
    G02874854Courtesy of SUBARU OF AMERICA, INC.
  4. Install fuel injector pipe.
  5. Connect left side fuel hose to injector pipe, and tighten clamp screw.
    Fig 3: Connecting Left Side Fuel Hose To Injector Pipe
    G02874855Courtesy of SUBARU OF AMERICA, INC.
  6. Connect air assist hoses.
    Fig 4: Connecting Air Assist Hoses
    G02874856Courtesy of SUBARU OF AMERICA, INC.
  7. Install fuel injectors.
    NOTE: Always use new o-rings.
    Fig 5: Installing Fuel Injectors
    G02874857Courtesy of SUBARU OF AMERICA, INC.
  8. Do not forget to install the fuel injector securing clip.
    Fig 6: Installing Fuel Injector Securing Clip
    G02874858Courtesy of SUBARU OF AMERICA, INC.
  9. Tighten bolt which installs injector pipe on intake manifold.
    1. Tightening torque:  5.0 N.m (0.51 kgf-m, 3.7 ft-lb)
      Fig 7: Tightening Injector Pipe Bolt
      G02874859Courtesy of SUBARU OF AMERICA, INC.
    1. Tightening torque:  19 N.m (1.9 kgf-m, 13.7 ft-lb)
      Fig 8: Tightening Bolts
      G02874860Courtesy of SUBARU OF AMERICA, INC.
  10. Tighten two bolts which install 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 9: Tightening Fuel Pipes Bolts
      G02874861Courtesy of SUBARU OF AMERICA, INC.
  11. Install purge control solenoid valve.
    1. Tightening torque:  16 N.m (1.6 kgf-m, 11.8 ft-lb)
    Fig 10: Installing Purge Control Solenoid Valve
    G02874862Courtesy of SUBARU OF AMERICA, INC.
  12. Connect hoses to purge control solenoid valve.
    CAUTION: Connect evaporation hoses as shown in the figure.
    Fig 11: Connecting Evaporation Hoses
    G02874863Courtesy 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 bands (A).
    Fig 12: Holding Engine Harness By Harness Bands
    G02874864Courtesy 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 fuel pipe protector RH.
    1. Tightening torque:  19 N.m (1.9 kgf-m, 13.7 ft-lb)
    Fig 13: Installing Fuel Pipe Protector RH
    G02874865Courtesy of SUBARU OF AMERICA, INC.
  17. Install fuel pipe protector LH.
    1. Tightening torque:  19 N.m (1.9 kgf-m, 13.7 ft-lb)
    Fig 14: Installing Fuel Pipe Protector LH
    G02874866Courtesy of SUBARU OF AMERICA, INC.
  18. Connect pressure regulator vacuum hose to intake manifold.
    Fig 15: Connecting Pressure Regulator Vacuum Hose To Intake Manifold
    G02874867Courtesy of SUBARU OF AMERICA, INC.
  19. Install air assist injector solenoid valve to bracket.

    < Ref. to INSTALLATION , Air Assist Injector Solenoid Valve.>

  20. Install EGR valve.

    < Ref. to INSTALLATION , EGR Valve.>

  21. Install throttle body to intake manifold.

    < Ref. to INSTALLATION , Throttle Body.>

  22. Install ignition coil and ignitor assembly.
    1. Tightening torque:  6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
    Fig 16: Installing Ignition Coil & Ignitor Assembly
    G02874868Courtesy of SUBARU OF AMERICA, INC.
  23. Connect connector to ignition coil and ignitor assembly.
  24. Install engine ground terminal to intake manifold.
    1. Tightening torque:  19 N.m (1.9 kgf-m, 13.7 ft-lb)
    Fig 17: Installing Engine Ground Terminal To Intake Manifold
    G02874869Courtesy of SUBARU OF AMERICA, INC.