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Home >> Subaru >> 2013 >> Forester XT Premium >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection System (H4DOTC) >> Intake Manifold >> Removal
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Intake Manifold: Removal

  1. Remove the collector cover.
  2. Collect the refrigerant from A/C system. < Refer to REFRIGERANT RECOVERY PROCEDURE , Refrigerant Recovery Procedure. >
  3. Release the fuel pressure. < Refer to RELEASING OF FUEL PRESSURE , PROCEDURE, Fuel. >
  4. Disconnect the ground cable from battery.
    Fig 1: Disconnecting/Connecting Battery Ground Cable
    G06336085Courtesy of SUBARU OF AMERICA, INC.
  5. Open the fuel filler lid and remove the fuel filler cap.
  6. Lift up the vehicle.
  7. Remove the under cover. < Refer to REMOVAL , Front Under Cover. >
  8. Drain approximately 3.0 L (3.2 US qt, 2.6 Imp qt) of coolant. < Refer to DRAINING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant. >
  9. Remove the air intake duct (rear) and air cleaner case. < Refer to REMOVAL , Air Intake Duct. > < Refer to REMOVAL , Air Cleaner Case. >
  10. Remove the intercooler. < Refer to REMOVAL , Intercooler. >
  11. Remove the generator. < Refer to REMOVAL , Generator. >
  12. Remove the coolant filler tank. < Refer to REMOVAL , Coolant Filler Tank. >
  13. Disconnect the A/C pressure hoses from A/C compressor. < Refer to REMOVAL , Hose and Pipe. >
  14. Disconnect the brake booster vacuum hose.
    Fig 2: Locating Brake Booster Vacuum Hose Clamp
    G08570657Courtesy of SUBARU OF AMERICA, INC.
  15. Remove the brake booster vacuum hose from the clip (A), and remove the bolts securing the air bypass pipe to the intake manifold.
    Fig 3: Locating Air Bypass Pipe Mounting Bolt
    G08570646Courtesy of SUBARU OF AMERICA, INC.
  16. Remove the bolts securing the PCV pipe assembly to the intake manifold, and remove the intake duct from the throttle body.
    Fig 4: Locating PCV Pipe Assembly Mounting Bolt
    G08539752Courtesy of SUBARU OF AMERICA, INC.
  17. Disconnect the engine coolant hose from throttle body.
    Fig 5: Locating Engine Coolant Hose Clamps
    G08539753Courtesy of SUBARU OF AMERICA, INC.
  18. Disconnect the vacuum hose from nipple.
    Fig 6: Locating Vacuum Hose Clamp
    G08539767Courtesy of SUBARU OF AMERICA, INC.
  19. Disconnect the air control hose (A) from the waste gate actuator, and loosen the clamp which holds the intake duct to the turbocharger.
    Fig 7: Identifying Air Control Hose
    G08539768Courtesy of SUBARU OF AMERICA, INC.
  20. Disconnect the connector (A) from the PCV hose assembly A and the connector (B) from the knock sensor.
    Fig 8: Identifying PCV Hose Assembly A And Knock Sensor Connectors
    G08539769Courtesy of SUBARU OF AMERICA, INC.
  21. Disconnect the connector from the PCV hose assembly B and PCV hose assembly C.
    Fig 9: Locating PCV Hose Assembly B And C Connector
    G08539770Courtesy of SUBARU OF AMERICA, INC.
  22. Disconnect the bulkhead harness connectors from the engine harness connectors.
    Fig 10: Locating Bulkhead Harness Connectors
    G08570665Courtesy of SUBARU OF AMERICA, INC.
  23. Remove the engine harness connector from the engine harness bracket.
    Fig 11: Locating Engine Harness Connector
    G08570666Courtesy of SUBARU OF AMERICA, INC.
  24. Disconnect the connector (A) from the engine coolant temperature sensor, connector (B) from the oil pressure switch, and connector (C) from the crankshaft position sensor.
    Fig 12: Identifying Engine Coolant Temperature Sensor, Oil Pressure Switch And Crankshaft Position Sensor Connectors
    G08539773Courtesy of SUBARU OF AMERICA, INC.
  25. Disconnect the connector from power steering pump switch.
    Fig 13: Locating Power Steering Pump Switch Connector
    G08538645Courtesy of SUBARU OF AMERICA, INC.
  26. Disconnect the connector from the secondary air combination valve.
    Fig 14: Locating Secondary Air Combination Valve Connectors
    G08539775Courtesy of SUBARU OF AMERICA, INC.
  27. Disconnect the connector from camshaft position sensor.
    Fig 15: Locating Camshaft Position Sensor Connector
    G08539776Courtesy of SUBARU OF AMERICA, INC.
  28. Disconnect the connector from the oil flow control solenoid valve.
    Fig 16: Locating Oil Flow Control Solenoid Valve Connectors
    G08539777Courtesy of SUBARU OF AMERICA, INC.
  29. Lift up the vehicle.
  30. Disconnect the connector from ignition coil.
    Fig 17: Locating Ignition Coil Connectors
    G08539778Courtesy of SUBARU OF AMERICA, INC.
  31. Lower the vehicle.
  32. Disconnect the connector from the front oxygen (A/F) sensor, and remove the clip (A) and stay (B) which hold the engine harness to the rocker cover RH.
    Fig 18: Locating Front Oxygen Sensor Connector With Clip And Stay
    G08539779Courtesy 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 19: Disconnecting Fuel Delivery Hose Using Quick Connector Release
    G08570674Courtesy 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 20: Connecting ST To Fuel Return Pipe
      G07910665Courtesy of SUBARU OF AMERICA, INC.
    2. Insert the front side of ST into the quick connector.
      Fig 21: Inserting ST Into Quick Connector
      G07910666Courtesy 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 22: Disconnecting Fuel Return Hose Using Special Tool
      G07910667Courtesy of SUBARU OF AMERICA, INC.
  35. Remove the clip and disconnect the evaporation hose from the fuel pipe.
    Fig 23: Locating Evaporation Hose Clip
    G06648763Courtesy of SUBARU OF AMERICA, INC.
  36. Remove the intake manifold from cylinder head.
    Fig 24: Locating Intake Manifold Mounting Bolts
    G08539785Courtesy of SUBARU OF AMERICA, INC.
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