Intake Manifold: Installation

Install the intake manifold onto cylinder heads.
NOTE: Use a new gasket.

Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)

Fig 1: Identifying Tumble Generator Valve Assembly And Cylinder Head
Courtesy of SUBARU OF AMERICA, INC.
Connect the fuel delivery hose, fuel return hose, and evaporation hose.
NOTE: If fuel hoses or clamps are damaged, replace them with new parts.

Fig 2: Connecting Fuel Delivery Hose, Fuel Return Hose And Evaporation Hose
Courtesy of SUBARU OF AMERICA, INC.
Connect the front oxygen (A/F) sensor connector, and secure the engine harness to the rocker cover RH with clip (A) and stay (B).
Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

Fig 3: Locating Front Oxygen (A/F) Sensor Connector
Courtesy of SUBARU OF AMERICA, INC.
Connect the connector to the ignition coil.

Fig 4: Locating Ignition Coil Connector
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Connect the air duct to the secondary air pump, and install the air duct on the rocker cover LH.
Tightening torque: 9 N.m (0.9 kgf-m, 6.6 ft-lb)

Fig 5: Locating Air Duct On Rocker Cover LH And Bolts
Courtesy of SUBARU OF AMERICA, INC.
Connect the connector to oil flow control solenoid valve.

Fig 6: Identifying Oil Flow Control Solenoid Valve To Connector
Courtesy of SUBARU OF AMERICA, INC.
Connect the connector to the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).

Fig 7: Identifying Engine Coolant Temperature Sensor, Oil Pressure Switch And Crankshaft Position Sensor Connectors
Courtesy of SUBARU OF AMERICA, INC.
Connect the connector to the knock sensor.

Fig 8: Disconnecting Knock Sensor Connector
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Connect the connector to the power steering pump switch.

Fig 9: Identifying Power Steering Pump Switch Connector
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Connect the connectors to camshaft position sensor.

Fig 10: Identifying Camshaft Position Sensor To Connectors
Courtesy of SUBARU OF AMERICA, INC.
Connect the connector to the secondary air combination valve.

Fig 11: Identifying Secondary Air Combination Valve To Connector
Courtesy of SUBARU OF AMERICA, INC.
Install the engine harness connector to engine harness bracket, then connect the bulkhead harness connector to the engine harness connector.

Fig 12: Identifying Bulkhead Harness Connector And Engine Harness Connector
Courtesy of SUBARU OF AMERICA, INC.
Connect the air control hose (A) to the waste-gate actuator, and install the turbocharger to the intake duct.
Tightening torque: 3 N.m (0.3 kgf-m, 2.2 ft-lb)
- Except for WRX-SS model
  
  Fig 13: Identifying Air Control Hose (Except For WRX-SS Model)
  Courtesy of SUBARU OF AMERICA, INC.
- WRX-SS model
Fig 14: Identifying Air Control Hose (WRX-SS Model)
Courtesy of SUBARU OF AMERICA, INC.
Connect the brake booster vacuum hose.

Fig 15: Identifying Brake Booster Vacuum Hose
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Connect the PCV hose to the rocker cover.
NOTE: Use a new clamp for the PCV hose clamp, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp.

ST 18353AA000 CLAMP PLIERS

Fig 16: Identifying ST Fitting Position Of Protrusion With Clamp
Courtesy of SUBARU OF AMERICA, INC.
Connect the engine coolant hoses to throttle body.

Fig 17: Identifying Engine Coolant Hoses
Courtesy of SUBARU OF AMERICA, INC.
Install the duct to the throttle body.
Tightening torque: 3 N.m (0.3 kgf-m, 2.2 ft-lb)
Attach the bolts which secure the air by-pass pipe and PCV pipe to the intake manifold.
Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

Fig 18: Locating Air By-Pass Pipe And PCV Pipe To Intake Manifold With Bolts
Courtesy of SUBARU OF AMERICA, INC.
Attach the connector to the PCV hose assembly.

Fig 19: Identifying PCV Hose Assembly Connector
Courtesy of SUBARU OF AMERICA, INC.
Connect the vacuum hose (A) and the connector (B) to the PCV hose assembly.

Fig 20: Identifying Vacuum Hose And Connector
Courtesy of SUBARU OF AMERICA, INC.
Install the A/C pressure hoses to A/C compressor. Refer to INSTALLATION , Hose and Pipe.
Install the coolant filler tank. Refer to INSTALLATION , Coolant Filler Tank.
Install the generator. Refer to INSTALLATION , Generator.
Install the intercooler. Refer to INSTALLATION , Intercooler.
Install the air intake boot.
Tightening torque: 2.5 N.m (0.3 kgf-m, 1.8 ft-lb)

Fig 21: Locating Air Intake Boot And Air Intake Duct
Courtesy of SUBARU OF AMERICA, INC.
Install the air intake duct. Refer to INSTALLATION , Air Intake Duct.
Connect the ground cable to battery.

Fig 22: Identifying Battery Ground Cable
Courtesy of SUBARU OF AMERICA, INC.
Lift up the vehicle.
Install the under cover.
Lower the vehicle.
Install the V-belt cover.
Tightening torque: 13 N.m (1.3 kgf-m, 9.6 ft-lb)

Fig 23: Locating V-Belt Covers
Courtesy of SUBARU OF AMERICA, INC.
Fill engine coolant. Refer to FILLING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant.
Charge the A/C system with refrigerant. Refer to PROCEDURE , Refrigerant Charging Procedure.