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Home >> Subaru >> 2004 >> Forester XS, Automatic >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection (Fuel Systems) (H4SO) >> Intake Manifold >> Removal
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Intake Manifold: Removal

  1. Release the fuel pressure. Refer to RELEASING OF FUEL PRESSURE , OPERATION, Fuel.
  2. Open the fuel filler flap lid, and remove the fuel filler cap.
  3. Disconnect the ground cable from battery.
    Fig 1: Disconnecting Ground Cable From Battery
    G00994711Courtesy of SUBARU OF AMERICA, INC.
  4. Remove the air intake duct and air cleaner case. Refer to REMOVAL , Air Intake Duct. Refer to REMOVAL , Air Cleaner Case.
  5. Disconnect the accelerator cable (A).
  6. Disconnect the cruise control cable (B). (With cruise control model)
    Fig 2: Disconnecting Cruise Control Cable With Cruise Control Model
    G00994712Courtesy of SUBARU OF AMERICA, INC.
  7. Remove the power steering pump and reservoir tank from bracket.
    1. Remove the resonator chamber. Refer to REMOVAL , Resonator Chamber.
    2. Remove the front side V-belt. Refer to REMOVAL REMOVAL, V-belt.
    3. Remove the bolts which hold power steering pipes onto the intake manifold protector.
      CAUTION: Do not disconnect the power steering hose. 
      Fig 3: Identifying Bolts & Power Steering Pipes
      G00994713Courtesy of SUBARU OF AMERICA, INC.
    4. Remove the bolts which secure power steering pump bracket.
      Fig 4: Identifying Bolts & Power Steering Pump Bracket
      G00994714Courtesy of SUBARU OF AMERICA, INC.
    5. Disconnect the connector from the power steering pump switch.
      Fig 5: Disconnecting Connector From Power Steering Pump Switch
      G00994715Courtesy of SUBARU OF AMERICA, INC.
    6. Remove the power steering tank from the bracket by pulling it upwards.
      Fig 6: Identifying Power Steering Tank From Bracket By Pulling It Upwards
      G00994716Courtesy of SUBARU OF AMERICA, INC.
    7. Place the power steering pump on the right side wheel apron.
      Fig 7: Placing Power Steering Pump On Right Side Wheel Apron
      G00994717Courtesy of SUBARU OF AMERICA, INC.
  8. Disconnect the spark plug cords from the spark plugs.
  9. Disconnect the PCV hose from the intake manifold.
    Fig 8: Disconnecting PCV Hose From Intake Manifold
    G00994718Courtesy of SUBARU OF AMERICA, INC.
  10. Disconnect the engine coolant hose (A) from the throttle body.
    Fig 9: Disconnecting Engine Coolant Hose From Throttle Body
    G00994719Courtesy of SUBARU OF AMERICA, INC.
  11. Disconnect the brake booster hose.
    Fig 10: Disconnecting Brake Booster Hose
    G00994720Courtesy of SUBARU OF AMERICA, INC.
  12. Remove the air cleaner case stay RH and engine harness bracket, and disconnect the engine harness connectors from the bulkhead harness connectors.
    Fig 11: Disconnecting Engine Harness Connectors From Bulkhead Harness Connectors
    G00994721Courtesy of SUBARU OF AMERICA, INC.
  13. Disconnect the connectors from the engine coolant temperature sensor.
    Fig 12: Disconnecting Connectors From Engine Coolant Temperature Sensor
    G00994722Courtesy of SUBARU OF AMERICA, INC.
  14. Disconnect the knock sensor connector.
    Fig 13: Disconnecting Knock Sensor Connector
    G00994723Courtesy of SUBARU OF AMERICA, INC.
  15. Disconnect the connector from the crankshaft position sensor.
    Fig 14: Disconnecting Connector From Crankshaft Position Sensor
    G00994724Courtesy of SUBARU OF AMERICA, INC.
  16. Disconnect the connector from the oil pressure switch.
    Fig 15: Disconnecting Connector From Oil Pressure Switch
    G00994725Courtesy of SUBARU OF AMERICA, INC.
  17. Disconnect the connector from the camshaft position sensor.
    Fig 16: Disconnecting Connector From Camshaft Position Sensor
    G00994726Courtesy of SUBARU OF AMERICA, INC.
  18. Remove the EGR pipe from intake manifold.
    Fig 17: Identifying EGR Pipe
    G00994727Courtesy of SUBARU OF AMERICA, INC.
  19. Disconnect the fuel hoses from the fuel pipes.
    WARNING:
    • Do not spill fuel. 
    • Catch fuel from hoses in a container or cloth. 
      Fig 18: Disconnecting Fuel Hoses From Fuel Pipes
      G00994728Courtesy of SUBARU OF AMERICA, INC.
  20. Remove the bolts which hold intake manifold onto the cylinder heads.
    Fig 19: Identifying Bolts & Intake Manifold
    G00994729Courtesy of SUBARU OF AMERICA, INC.
  21. Remove the intake manifold.