Intake Manifold: Assembly

1. Install intake manifold RH and LH to tumble generator valve assembly.
   NOTE: Always use a new gasket.
   CAUTION: This work should be done on cylinder head. (Do not use gasket for the mating surface of cylinder head and intake manifold at this time.) 
   1. Temporarily tighten (a) - (o) in alphabetical order.
   2. Tighten (e) - (k) to 5 N.m (0.5 kgf-m, 4 ft-lb).
   3. Tighten (a) - (d) and (l) - (o) to 10 N.m (1.0 kgf-m, 7 ft-lb).
   4. Tighten (e) - (g) to 25 N.m (2.6 kgf-m, 18 ft-lb).
   5. Tighten (h) - (k) to 25 N.m (2.6 kgf-m, 18 ft-lb).
   6. Loosen (a) - (d) and (l) - (o) to remove.
   Fig 1: Installing Intake Manifold RH & LH To Tumble Generator Valve Assembly

   Courtesy of SUBARU OF AMERICA, INC.
2. Tighten bolt which pressure regulator to intake manifold.

   Tightening torque: 

   5.0 N.m (0.51 kgf-m, 3.7 ft-lb) 

3. Tighten bolt which installs fuel pipes on intake manifold.

   Tightening torque: 

   5.0 N.m (0.51 kgf-m, 3.7 ft-lb) 

   Fig 2: Tightening Bolt Which Installs Fuel Pipes On Intake Manifold

   Courtesy of SUBARU OF AMERICA, INC.
4. Connect fuel injector pipe to fuel hose, and tighten clamp screw.
   NOTE: Tighten clamp screw as shown in the Figure below.

   L: 2 - 5 mm (0.08 - 0.20 in) 

   Fig 3: Tightening Clamp Screw

   Courtesy of SUBARU OF AMERICA, INC.

   Tightening torque: 

   1.5 N.m (0.15 kgf-m, 1.1 ft-lb) 

   • LH side
     Fig 4: Tightening Torque LH Side (1 Of 2)

     Courtesy of SUBARU OF AMERICA, INC.
   • RH side
   Fig 5: Tightening Torque RH Side (2 Of 2)

   Courtesy of SUBARU OF AMERICA, INC.
5. Install fuel injectors.
6. Tighten bolt which installs injector pipe on intake manifold.
   • RH side

     Tightening torque: 

     19 N.m (1.9 kgf-m, 13.7 ft-lb) 

     Fig 6: Installing Injector Pipe On Intake Manifold

     Courtesy of SUBARU OF AMERICA, INC.
   • LH side

   Tightening torque: 

   19 N.m (1.9 kgf-m, 13.7 ft-lb) 

   Fig 7: Installing Injector Pipe On Intake Manifold (LH Side)

   Courtesy of SUBARU OF AMERICA, INC.

   Tightening torque: 

   5.0 N.m (0.51 kgf-m, 3.7 ft-lb) 

   Fig 8: Installing Injector Pipe On Intake Manifold (RH Side)

   Courtesy of SUBARU OF AMERICA, INC.
7. Hold engine harness by harness bands.
   Fig 9: Holding Engine Harness By Harness Bands (1 Of 2)

   Courtesy of SUBARU OF AMERICA, INC.
   Fig 10: Holding Engine Harness By Harness Bands (2 Of 2)

   Courtesy of SUBARU OF AMERICA, INC.
8. Install purge control solenoid valve. Refer to INSTALLATION , Purge Control Solenoid Valve.
9. Install tumble generator valve actuator. Refer to TUMBLE GENERATOR VALVE ACTUATOR .
10. Connect connector (A) to fuel injector.
11. Secure engine harness on injector pipe by harness band (B).
    Fig 11: Connecting Connector To Fuel Injector

    Courtesy of SUBARU OF AMERICA, INC.
12. Install fuel pipe protector RH.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 13.7 ft-lb) 

    Fig 12: Installing Fuel Pipe Protector RH

    Courtesy of SUBARU OF AMERICA, INC.
13. Install fuel pipe protector LH.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 13.7 ft-lb) 

    Fig 13: Installing Fuel Pipe Protector LH

    Courtesy of SUBARU OF AMERICA, INC.
14. Connect pressure regulator vacuum hose to intake manifold.
    Fig 14: Connecting Pressure Regulator Vacuum Hose To Intake Manifold

    Courtesy of SUBARU OF AMERICA, INC.
15. Install PCV pipe.

    Tightening torque: 

    5.0 N.m (0.51 kgf-m, 3.7 ft-lb) 

    Fig 15: Installing PCV Pipe

    Courtesy of SUBARU OF AMERICA, INC.
16. Install EGR valve. Refer to EGR VALVE .
17. Install throttle body to intake manifold. Refer to THROTTLE BODY .
18. Install ignition coil and ignitor assembly. Refer to INSTALLATION , Ignition Coil and Ignitor Assembly.
19. Install engine ground terminal to intake manifold.

Tightening torque: 

19 N.m (1.9 kgf-m, 13.7 ft-lb) 

• LH side
  Fig 16: Installing Engine Ground Terminal To Intake Manifold (LH side)

  Courtesy of SUBARU OF AMERICA, INC.
• RH side
  Fig 17: Installing Engine Ground Terminal To Intake Manifold (RH Side)

  Courtesy of SUBARU OF AMERICA, INC.