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Intake Manifold: Installation

  1. Connect the connectors to the engine, and install the engine harness.
    NOTE: Refer to "COMPONENT" of "General Description" for how to connect the engine harness connectors. < Refer to ENGINE HARNESS , COMPONENT, General Description. >

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 1: Locating Engine Harness Mounting Bolts
    G08562580Courtesy of SUBARU OF AMERICA, INC.
  2. Install the intake manifold to the tumble generator valve assembly.
    NOTE: Use a new gasket.

    Tightening torque: 

    8.3 N.m (0.8 kgf-m, 6.1 ft-lb) 

    Fig 2: Locating Tumble Generator Valve Assembly Mounting Bolts
    G08562579Courtesy of SUBARU OF AMERICA, INC.
  3. Connect the fuel delivery hose (A) and evaporation hose (B).
    Fig 3: Identifying Fuel Delivery And Evaporation Hose
    G08562583Courtesy of SUBARU OF AMERICA, INC.
  4. Connect the fuel delivery pipe to the fuel pipe LH.
    CAUTION:
    • Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.
    • When connecting the quick connector, make sure to insert the pipe all the way in before locking the slider.
    • When it is difficult to lock the slider, check that the pipe is fully inserted.
    • Make sure that the quick connector is securely connected.
    NOTE: Connect the quick connector as shown in the figure.
    Fig 4: Connecting Quick Connector
    G08562584Courtesy of SUBARU OF AMERICA, INC.
    Fig 5: Locating Quick Connector
    G08315345Courtesy of SUBARU OF AMERICA, INC.
  5. Install the intake manifold protector LH.

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 6: Locating Intake Manifold Protector Bolts (LH)
    G08562575Courtesy of SUBARU OF AMERICA, INC.
  6. Connect the fuel delivery pipe to the fuel pipe RH.
    CAUTION:
    • Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.
    • When connecting the quick connector, make sure to insert the pipe all the way in before locking the slider.
    • When it is difficult to lock the slider, check that the pipe is fully inserted.
    • Make sure that the quick connector is securely connected.
    NOTE: Connect the quick connector as shown in the figure.
    Fig 7: Connecting Quick Connector
    G08562587Courtesy of SUBARU OF AMERICA, INC.
    Fig 8: Locating Quick Connector
    G08315342Courtesy of SUBARU OF AMERICA, INC.
  7. Install the intake manifold protector RH.

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 9: Locating Intake Manifold Protector Bolts (RH)
    G08562572Courtesy of SUBARU OF AMERICA, INC.
  8. Install the air intake case (rear).
    Fig 10: Locating Air Cleaner Case Clamps
    G08562571Courtesy of SUBARU OF AMERICA, INC.
  9. Install the clip (B) which secures the air flow and intake air temperature sensor harness, and connect the connector (A) to the air flow and intake air temperature sensor.
  10. Install the suction hose (C) to the air cleaner case (rear).
    Fig 11: Identifying Mass Air Flow And Intake Air Temperature Sensor Connector, Clip And Suction Hose
    G08562570Courtesy of SUBARU OF AMERICA, INC.
  11. Connect the brake booster vacuum hose to the intake manifold.
    Fig 12: Locating Brake Booster Vacuum Hose Clamp
    G08562569Courtesy of SUBARU OF AMERICA, INC.
  12. Connect the vacuum hose (A) to the intake manifold.
  13. Connect the connector (B) to the manifold absolute pressure sensor.
  14. Connect the connector (C) to the throttle position sensor.
    Fig 13: Identifying Vacuum Hose, Manifold Absolute Pressure And Throttle Position Sensor Connector
    G08562568Courtesy of SUBARU OF AMERICA, INC.
  15. Connect the connector (A) to the purge control solenoid valve.
  16. Hold the PCV hose assembly with clip (B).
  17. Tighten the nut (C) and bolt (D) which hold EGR pipe to the water pipe assembly.
    NOTE:
    • Use a new gasket.
    • Always tighten the EGR pipe at (C) first, and then (D).

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 14: Identifying Purge Control Solenoid Valve Connector, Clip, Nut And Bolt
    G08562567Courtesy of SUBARU OF AMERICA, INC.
  18. Install the preheater hose.
    Fig 15: Locating Preheater Hose Clips
    G08562566Courtesy of SUBARU OF AMERICA, INC.
  19. Install the air intake boot. < Refer to INSTALLATION , Air Intake Boot. >
  20. Lift up the vehicle.
  21. Install the under cover RH. < Refer to INSTALLATION , Front Under Cover. >
  22. Lower the vehicle.
  23. Connect the battery ground terminal.
    Fig 16: Connecting/Disconnecting Battery Ground Terminal
    G08570271Courtesy of SUBARU OF AMERICA, INC.
  24. Fill engine coolant. < Refer to FILLING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant. >
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