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Home >> Subaru >> 2009 >> Forester XT >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection System (H4DOTC) >> Intake Manifold >> Removal
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Intake Manifold: Removal

  1. Set the vehicle on a lift.
  2. Remove the collector cover.
  3. Collect the refrigerant from the A/C system. Refer to PROCEDURE , Refrigerant Recovery Procedure .
  4. Release the fuel pressure. Refer to RELEASING OF FUEL PRESSURE , PROCEDURE, Fuel .
  5. Disconnect the battery cable, and remove the battery from the vehicle.
  6. Open the fuel filler lid, and remove the fuel filler cap.
  7. Lift up the vehicle.
  8. Remove the under cover.
  9. Drain approximately 3.0 l  (3.2 US qt, 2.6 lmp qt) of coolant. Refer to DRAINING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant .
  10. Remove the air intake duct (rear) and air cleaner case. Refer to REMOVAL , Air Cleaner Case . Refer to REMOVAL , Air Intake Duct .
  11. Remove the intercooler. Refer to REMOVAL , Intercooler .
  12. Remove the generator. Refer to REMOVAL , Generator .
  13. Remove the coolant filler tank. Refer to REMOVAL , Coolant Filler Tank .
  14. Disconnect the A/C pressure hoses from A/C compressor. Refer to REMOVAL , Hose and Pipe .
  15. Disconnect the vacuum hose (A) and the connector (B) from the PCV hose assembly.
    Fig 1: Identifying Vacuum Hose And Connector
    G05954723Courtesy of SUBARU OF AMERICA, INC.
  16. Remove the connector from the PCV hose assembly.
    Fig 2: Identifying PCV Hose Assembly Connector
    G05954724Courtesy of SUBARU OF AMERICA, INC.
  17. Remove the bolts which secure the air by-pass pipe and PCV pipe to the intake manifold, and loosen the clamp which connects the throttle body and duct.
    Fig 3: Locating Air By-Pass Pipe Bolts
    G05340064Courtesy of SUBARU OF AMERICA, INC.
  18. Remove the duct from the throttle body.
  19. Disconnect the engine coolant hoses from the throttle body.
    Fig 4: Identifying Engine Coolant Hoses
    G05954721Courtesy of SUBARU OF AMERICA, INC.
  20. Disconnect the brake booster vacuum hose.
    Fig 5: Identifying Brake Booster Vacuum Hose
    G05954727Courtesy of SUBARU OF AMERICA, INC.
  21. Disconnect the PCV hose from the rocker cover.
    NOTE: Fit the cut out in the ST with the protrusion on the clamp as shown in the figure, unlock the clamp, and disconnect the PCV hose fastened by the clamp.

    ST 18353AA000 CLAMP PLIERS

    Fig 6: Identifying PCV Hose Clamp
    G05340073Courtesy of SUBARU OF AMERICA, INC.
  22. Disconnect the air control hose (A) from the wastegate actuator, and loosen the clamp that holds the turbocharger on the intake duct.
    Fig 7: Identifying Air Control Hose With Bolt
    G05954729Courtesy of SUBARU OF AMERICA, INC.
  23. Disconnect the engine harness connectors from the bulk head harness connector.
    Fig 8: Identifying Engine Harness Connectors
    G05954730Courtesy of SUBARU OF AMERICA, INC.
  24. Disconnect the connectors from the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).
    Fig 9: Identifying Engine Coolant Temperature Sensor, Oil Pressure Switch And Crankshaft Position Sensor
    G04998268Courtesy of SUBARU OF AMERICA, INC.
  25. Disconnect the connector from power steering pump switch.
    Fig 10: Identifying Power Steering Pump Switch Connector
    G05340076Courtesy of SUBARU OF AMERICA, INC.
  26. Disconnect the knock sensor connector.
    Fig 11: Identifying Knock Sensor Connector
    G05954733Courtesy of SUBARU OF AMERICA, INC.
  27. Disconnect the connector from the secondary air combination valve.
    Fig 12: Identifying Secondary Air Combination Valve Connector
    G05954734Courtesy of SUBARU OF AMERICA, INC.
  28. Disconnect the connector from the camshaft position sensor.
    Fig 13: Identifying Camshaft Position Sensor Connector
    G05954735Courtesy of SUBARU OF AMERICA, INC.
  29. Disconnect the connector from the oil flow control solenoid valve.
    Fig 14: Identifying Oil Flow Control Solenoid Valve Connector
    G05954736Courtesy of SUBARU OF AMERICA, INC.
  30. Disconnect the air duct from the secondary air pump, and remove the bolts that install the air duct on the rocker cover LH.
    Fig 15: Locating Air Duct With Bolt
    G05954737Courtesy of SUBARU OF AMERICA, INC.
  31. Disconnect the connector from ignition coil.
    Fig 16: Locating Ignition Coil Connector
    G05954738Courtesy of SUBARU OF AMERICA, INC.
  32. Remove the engine harness fixed by clip (A) from the rocker cover.
    Fig 17: Identifying Engine Harness Clip
    G05954739Courtesy of SUBARU OF AMERICA, INC.
  33. Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose.

    ST 42099AE000 QUICK CONNECTOR RELEASE

    CAUTION:
    • Be careful not to spill fuel.
    • Catch the fuel from hoses using a container or cloth.
    Fig 18: Identifying Fuel Delivery And Return Hose
    G05954740Courtesy of SUBARU OF AMERICA, INC.
  34. Disconnect the fuel return hose using the ST.

    ST 18371AA000 CONNECTOR REMOVER

    CAUTION:
    • Be careful not to spill fuel.
    • Catch the fuel from hoses using a container or cloth.
    1. Attach ST to the fuel return pipe as shown in the figure.
      Fig 19: Identifying Connector Remover (18371AA000)
      G05340084Courtesy of SUBARU OF AMERICA, INC.
    2. Insert the front side of ST into the quick connector.
      Fig 20: Inserting Front Side Of ST Into Quick Connector
      G05340085Courtesy of SUBARU OF AMERICA, INC.
    3. Insert the back side of ST into the quick connector and push ST in the direction of arrow mark to disconnect the fuel return hose.
    Fig 21: Inserting Back Side Of ST Into Quick Connector
    G05340086Courtesy of SUBARU OF AMERICA, INC.
  35. Remove the clip and disconnect the evaporation hose from the fuel pipe.
    Fig 22: Identifying Evaporation Hose
    G05340087Courtesy of SUBARU OF AMERICA, INC.
  36. Remove the bolts which hold the tumble generator valve assembly onto the cylinder head.
    Fig 23: Locating Tumble Generator Valve Assembly Bolts
    G05340088Courtesy of SUBARU OF AMERICA, INC.
  37. Remove the intake manifold.
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