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Home >> Subaru >> 2004 >> Forester XT, Automatic >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection (Fuel Systems) (H4DOTC) >> Intake Manifold >> Assembly
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Intake Manifold: Assembly

NOTE: Replace the gasket with a new one.
  1. Install the tumble generator valve assembly to the intake manifold.
    1. Tightening torque: 8.25 N.m (0.84 kgf-m, 6.1 ft-lb) 
    Fig 1: Identifying Tumble Generator Valve Assembly
    G00966302Courtesy of SUBARU OF AMERICA, INC.
  2. Install the air intake duct to the intake manifold.
    1. Tightening torque: 19 N.m (1.94 kgf-m, 13.7 ft-lb) 
    Fig 2: Identifying Air Intake Duct
    G00966303Courtesy of SUBARU OF AMERICA, INC.
  3. Install the fuel pipe assembly and pressure regulator to the intake manifold.
    1. Tightening torque: 4.9 N.m (0.5 kgf-m, 3.6 ft-lb) 
    Fig 3: Identifying Fuel Pipe Assembly & Pressure Regulator
    G00966304Courtesy of SUBARU OF AMERICA, INC.
  4. Install the fuel injector pipe LH.
  5. Connect the left side fuel hose to injector pipe, and tighten the clamp screw.
    Fig 4: Identifying Left Side Fuel Hose
    G00966305Courtesy of SUBARU OF AMERICA, INC.
  6. Install the fuel injector pipe RH.
  7. Connect the right side fuel hose to injector pipe, and tighten the clamp screw.
    Fig 5: Identifying Right Side Fuel Hose
    G00966306Courtesy of SUBARU OF AMERICA, INC.
  8. Install the engine harness to the intake manifold.
  9. Install the harness bracket which holds the engine harness onto intake manifold.
    1. Tightening torque: 19 N.m (1.94 kgf-m, 13.7 ft-lb) 
    Fig 6: Identifying Harness Bracket
    G00966307Courtesy of SUBARU OF AMERICA, INC.
  10. Tighten the bolts which install the fuel injector pipe onto intake manifold.
    1. Tightening torque: 19 N.m(1.94 kgf-m, 13.7 ft-lb) 
    • LH SIDE
      Fig 7: Tightening Bolts LH Side (1 Of 2)
      G00966308Courtesy of SUBARU OF AMERICA, INC.
      Fig 8: Tightening Bolt LH Side (2 Of 2)
      G00966309Courtesy of SUBARU OF AMERICA, INC.
    • RH SIDE
      Fig 9: Tightening Bolts RH Side (1 Of 2)
      G00966310Courtesy of SUBARU OF AMERICA, INC.
      Fig 10: Tightening Bolt RH Side (2 Of 2)
      G00966311Courtesy of SUBARU OF AMERICA, INC.
  11. Tighten the two bolts which install the fuel pipes on the left side of intake manifold.
    1. Tightening torque: 4.9 N.m (0.5 kgf-m, 3.6 ft-lb) 
    Fig 11: Tightening Bolts On Intake Manifold
    G00966312Courtesy of SUBARU OF AMERICA, INC.
  12. Connect the evaporation hoses to the purge valve.
    NOTE: Connect the evaporation hoses as shown in the figure.
    Fig 12: Identifying Evaporation Hoses
    G00966313Courtesy of SUBARU OF AMERICA, INC.
  13. Connect the evaporation hose and purge valve to the intake manifold.
    Fig 13: Identifying Evaporation Hose & Purge Valve
    G00966314Courtesy of SUBARU OF AMERICA, INC.
  14. Install the purge control solenoid valve.
    1. Tightening torque: 16 N.m (1.6 kgf-m, 11.8 ft-lb) 
    Fig 14: Identifying Purge Control Solenoid Valve
    G00966315Courtesy of SUBARU OF AMERICA, INC.
  15. Connect the hoses to the purge control solenoid valve.
    NOTE: Connect the evaporation hoses as shown in the figure.
    Fig 15: Identifying Evaporation Hoses
    G00966316Courtesy of SUBARU OF AMERICA, INC.
  16. Connect the connectors to the purge control solenoid valve.
  17. Connect the connectors to the tumble generator valve sensor.
    Fig 16: Identifying Tumble Generator Valve Sensor
    G00966317Courtesy of SUBARU OF AMERICA, INC.
  18. Connect the connectors to the tumble generator valve actuator.
    Fig 17: Identifying Tumble Generator Valve Actuator
    G00966318Courtesy of SUBARU OF AMERICA, INC.
  19. Connect the connectors to the fuel injector.
    Fig 18: Identifying Fuel Injector
    G00966319Courtesy of SUBARU OF AMERICA, INC.
  20. Install the throttle body to the intake manifold.
    NOTE: Replace the gasket with a new one.
    1. Tightening torque: 8 N.m (0.8 kgf-m, 5.8 ft-lb) 
    Fig 19: Identifying Throttle Body
    G00966320Courtesy of SUBARU OF AMERICA, INC.
  21. Connect the connectors to the throttle position sensor (A) and manifold absolute pressure sensor (B).
    Fig 20: Identifying Throttle Position Sensor & Manifold Absolute Pressure Sensor
    G00966321Courtesy of SUBARU OF AMERICA, INC.
  22. Install the engine ground terminal to the intake manifold.
    1. Tightening torque: 19 N.m (1.94 kgf-m, 13.7 ft-lb) 
    Fig 21: Identifying Engine Ground Terminal (1 Of 2)
    G00966322Courtesy of SUBARU OF AMERICA, INC.
    Fig 22: Identifying Engine Ground Terminal (2 Of 2)
    G00966323Courtesy of SUBARU OF AMERICA, INC.
  23. Install the fuel pipe protector RH.
    1. Tightening torque:19 N.m (1.94 kgf-m, 13.7 ft-lb) 
    Fig 23: Identifying Fuel Pipe Protector RH
    G00966324Courtesy of SUBARU OF AMERICA, INC.
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