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Intake Manifold: Removal

  1. Remove the collector cover.
  2. Release the fuel pressure. < Ref. to RELEASING OF FUEL PRESSURE , PROCEDURE, Fuel. >
  3. Remove the battery and battery carrier. < Ref. to REMOVAL , Battery. >
  4. Open the fuel filler lid and remove the fuel filler cap.
  5. Disconnect the brake booster vacuum hose from the intake manifold.
    Fig 1: Identifying Brake Booster Vacuum Hose
    G08543837Courtesy of SUBARU OF AMERICA, INC.
  6. Remove the air cleaner case and intake boot. < Ref. to REMOVAL , Air Cleaner Case. >
  7. Loosen the clamp (A) which connects air intake chamber to throttle body.
  8. Remove the bolt (B) which secures air intake chamber and collector cover bracket to the stay.
    Fig 2: Identifying Air Intake Chamber Clamp And Bolt
    G08543848Courtesy of SUBARU OF AMERICA, INC.
  9. Remove the air intake chamber, and move it to the left side wheel apron.
    Fig 3: Identifying Air Intake Chamber
    G08543839Courtesy of SUBARU OF AMERICA, INC.
  10. Disconnect the following connector.
    1. Remove the securing clips from the two locations on the fuel pipe protector LH.
      Fig 4: Locating Fuel Pipe Protector Clips
      G07924386Courtesy of SUBARU OF AMERICA, INC.
    2. Generator connector
    3. Generator terminal B
    4. Remove the harness cover from collector cover bracket.
    5. Magnet clutch connector
      Fig 5: Identifying Magnet Clutch Connector, Generator Connector, Harness Cover And Terminal B
      G08543851Courtesy of SUBARU OF AMERICA, INC.
    6. Slide the harness and connector to the battery side.
  11. Disconnect the PCV hose.
    Fig 6: Locating PCV Hose
    G08543852Courtesy of SUBARU OF AMERICA, INC.
  12. Disconnect the connector from the throttle body.
    Fig 7: Identifying Throttle Body Connector
    G07924389Courtesy of SUBARU OF AMERICA, INC.
  13. Disconnect the engine harness connector.
    Fig 8: Locating Engine Harness Connector
    G07924390Courtesy of SUBARU OF AMERICA, INC.
  14. Remove the throttle body from the intake manifold.
    NOTE: Do not disconnect the inlet and outlet hoses of engine coolant.
    Fig 9: Locating Throttle Body Mounting Bolts
    G08543842Courtesy of SUBARU OF AMERICA, INC.
  15. Disconnect the fuel delivery hose and evaporation hose.
    CAUTION:
    • Be careful not to spill fuel.
    • Catch the fuel from hoses using a container or cloth.
    1. Disconnect the quick connector of the fuel delivery hose by pushing the ST in the direction of the arrow.

      ST 42099AE000 QUICK CONNECTOR RELEASE

      Fig 10: Disconnecting Fuel Delivery Hose Quick Connector Using ST
      G08543856Courtesy of SUBARU OF AMERICA, INC.
    2. Remove the clip and disconnect the evaporation hose.
  16. Remove the fuel pipe protector LH.
    Fig 11: Locating Fuel Pipe Protector Bolts (LH)
    G07924394Courtesy of SUBARU OF AMERICA, INC.
  17. Disconnect #2, #4, and #6 fuel injector connectors.
  18. Disconnect the connectors of the oil temperature sensor, engine coolant temperature sensor and intake oil flow control solenoid valve LH.
    Fig 12: Identifying Intake Oil Flow Control Solenoid Valve LH, Oil Temperature And Engine Coolant Temperature Sensor
    G08543858Courtesy of SUBARU OF AMERICA, INC.
  19. Remove the bolts which hold fuel injector pipe LH to cylinder head.
    Fig 13: Locating Fuel Injector Pipe LH To Cylinder Head Mounting Bolts
    G07924396Courtesy of SUBARU OF AMERICA, INC.
  20. Disconnect the connectors of the intake oil flow control solenoid valve RH.
    Fig 14: Identifying Intake Oil Flow Control Solenoid Valve Connector (RH)
    G07924397Courtesy of SUBARU OF AMERICA, INC.
  21. Remove the feed hose from the fuel pipe protector RH.
    Fig 15: Identifying Feed Hose Mounting Bolt
    G07924398Courtesy of SUBARU OF AMERICA, INC.
  22. Remove the fuel pipe protector RH.
    Fig 16: Locating Fuel Pipe Protector Bolts (RH)
    G07924399Courtesy of SUBARU OF AMERICA, INC.
  23. Disconnect #1, #3, and #5 fuel injector connectors.
  24. Remove the bolts which hold the fuel injector pipe RH to the cylinder head.
    Fig 17: Locating Bolts Holding Fuel Injector Pipe RH To Cylinder Head
    G07912261Courtesy of SUBARU OF AMERICA, INC.
  25. Remove the bolts which hold the intake manifold to the cylinder head.
    • LH side
      Fig 18: Locating Bolts Holding Intake Manifold To Cylinder Head (LH Side)
      G07924401Courtesy of SUBARU OF AMERICA, INC.
    • RH side
      Fig 19: Locating Bolts Holding Intake Manifold To Cylinder Head (RH Side)
      G07912263Courtesy of SUBARU OF AMERICA, INC.
  26. Remove the EGR pipe securing bolt.
    Fig 20: Locating EGR Pipe Securing Bolts
    G07912264Courtesy of SUBARU OF AMERICA, INC.
  27. Remove the engine harness from the fuel injector pipe RH.
    Fig 21: Locating Engine Harness Clamps Fuel Injector Pipe RH
    G07912265Courtesy of SUBARU OF AMERICA, INC.
  28. Remove the engine harness from the fuel injector pipe LH.
    Fig 22: Locating Engine Harness Clamps Fuel Injector Pipe LH
    G07912266Courtesy of SUBARU OF AMERICA, INC.
  29. Remove the intake manifold.