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Home >> Subaru >> 2015 >> Forester 2.5i Limited, Eng CD FB25BA >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection Fuel Systems (H4DO) >> Intake Manifold >> Installation
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Intake Manifold: Installation

  1. Install the engine wiring harness. < Ref. to INSTALLATION , Engine Wiring Harness. >
  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 1: Locating Intake Manifold Bolts
    G09475488Courtesy of SUBARU OF AMERICA, INC.
  3. Connect the fuel delivery tube and evaporation hose.
    1. Connect the evaporation hose to fuel pipe assembly.
      Fig 2: Locating Evaporation Hose
      G09475487Courtesy of SUBARU OF AMERICA, INC.
    2. Connect the quick connector on the fuel delivery tube to the fuel pipe assembly, and fix the fuel delivery tube using clip (A).
    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 3: Connecting Quick Connector
    G09475491Courtesy of SUBARU OF AMERICA, INC.
    Fig 4: Locating Quick Connector
    G09475486Courtesy 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 5: Connecting Quick Connector
    G09475493Courtesy of SUBARU OF AMERICA, INC.
    Fig 6: 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 7: Locating Intake Manifold Protector Bolts
    G08315343Courtesy 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 8: Connecting Quick Connector
    G09475496Courtesy of SUBARU OF AMERICA, INC.
    Fig 9: 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 10: Locating Intake Manifold Protector Bolts
    G08315340Courtesy of SUBARU OF AMERICA, INC.
  8. Install the air intake case (rear).
    Fig 11: Installing Air Cleaner Case
    G09475478Courtesy 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.
    Fig 12: Identifying Air Flow And Intake Air Temperature Sensor Harness Connector And Clip
    G09475477Courtesy of SUBARU OF AMERICA, INC.
  10. Connect the brake booster vacuum hose to the intake manifold.
    Fig 13: Locating Brake Booster Vacuum Hose Clamp
    G09475476Courtesy of SUBARU OF AMERICA, INC.
  11. Connect the PCV hose (A) to intake manifold.
  12. Connect the connector (B) to the manifold absolute pressure sensor.
  13. Connect the connector (C) to the throttle position sensor.
    Fig 14: Identifying Throttle Position Sensor, Manifold Absolute Pressure Sensor Connector And Intake Manifold PCV Hose
    G08315336Courtesy of SUBARU OF AMERICA, INC.
  14. Connect the connector (A) to the purge control solenoid valve.
  15. Tighten the nut (C) and bolt (B) which hold EGR pipe to the water pipe assembly.
    NOTE:
    • Use a new gasket.
    • Always tighten the EGR pipe at (C) first, and then (B).

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 15: Identifying EGR Pipe Nut And Bolts
    G08315335Courtesy of SUBARU OF AMERICA, INC.
  16. Connect the preheater hoses to the throttle body.
    Fig 16: Locating Throttle Body Preheater Hose Clamps
    G08315334Courtesy of SUBARU OF AMERICA, INC.
  17. Install the air intake boot. < Ref. to INSTALLATION , Air Intake Boot. >
  18. Lift up the vehicle.
  19. Install the under cover. < Ref. to INSTALLATION , Front Under Cover. >
  20. Lower the vehicle.
  21. Connect the battery ground terminal.
  22. Fill engine coolant. < Ref. to FILLING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant. >
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