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Home >> Subaru >> 2016 >> Outback 2.5i >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection System (H4DO) >> Intake Manifold Assembly >> Installation
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Intake Manifold Assembly: Installation

  1. Install the intake manifold assembly onto cylinder head.
    NOTE:
    • Use a new gasket.
    • Be careful not to let the engine harness be caught by the parts.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.4 ft-lb) 

    Fig 1: Locating Intake Manifold Assembly Bolts
    G10262127Courtesy of SUBARU OF AMERICA, INC.
  2. Connect the fuel delivery tube and evaporation hose.
    1. Connect the evaporation hose (C) to the fuel pipe assembly.
    2. Connect the connector of the fuel delivery tube (B) to the fuel pipe assembly, and secure 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.
      • Make sure that the quick connector is securely connected.
      Fig 2: Connecting Evaporation Hose To Fuel Pipe Assembly
      G10262129Courtesy of SUBARU OF AMERICA, INC.
  3. 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 it all the way in before locking the slider.
    • When it is difficult to lock the slider, check that the connector is fully inserted.
    • After locking the slider, check again that the quick connector is securely connected.
    NOTE: Connect the quick connector as shown in the figure.
    Fig 3: Connecting Quick Connector
    G10307851Courtesy of SUBARU OF AMERICA, INC.
  4. Connect the connector (A) to the tumble generator valve, and connect the connector (B) to the fuel injector #4.
    Fig 4: Identifying Tumble Generator Valve And Fuel Injector Connector
    G10262125Courtesy of SUBARU OF AMERICA, INC.
  5. Install the intake manifold protector LH, and install the clip (A) securing the engine harness to the intake manifold protector LH.

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 5: Identifying Engine Harness Clip
    G10262123Courtesy of SUBARU OF AMERICA, INC.
  6. Install the clip (A) securing the engine harness to the intake manifold assembly, and connect the connector (B) to the tumble generator valve and connect the connector (C) to the fuel injector #3.
  7. 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 it all the way in before locking the slider.
    • When it is difficult to lock the slider, check that the connector is fully inserted.
    • After locking the slider, check again that the quick connector is securely connected.
    NOTE: Connect the quick connector as shown in the figure.
    Fig 6: Connecting Quick Connector
    G10307854Courtesy of SUBARU OF AMERICA, INC.
    Fig 7: Locating Intake Manifold Protector LH Bolt
    G10262122Courtesy of SUBARU OF AMERICA, INC.
  8. Install the intake manifold protector RH.

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 8: Locating Intake Manifold Protector RH Bolt
    G10262120Courtesy of SUBARU OF AMERICA, INC.
  9. Connect the connector to the EGR control valve.
    Fig 9: Locating EGR Control Valve Connector
    G10262119Courtesy of SUBARU OF AMERICA, INC.
  10. Install the air cleaner case (rear) together with the air cleaner element. < Ref. to INSTALLATION , Air Cleaner Case. >
  11. Secure the bulkhead wiring harness with clip (B) and connect the connector (A) to the mass air flow and intake air temperature sensor.
    Fig 10: Identifying Bulkhead Wiring Harness Clip And Connector
    G10262137Courtesy of SUBARU OF AMERICA, INC.
  12. Install the air intake duct. < Ref. to INSTALLATION , Air Intake Duct. >
  13. Connect the brake booster vacuum hose (A) and the connector (B) of the purge control solenoid valve.
    Fig 11: Identifying Brake Booster Vacuum Hose And Purge Control Solenoid Valve Connector
    G10262117Courtesy of SUBARU OF AMERICA, INC.
  14. Tighten the bolt securing the EGR cooler to the EGR control valve.
    NOTE: Use a new gasket.

    Tightening torque: 

    T1: 9 N.m (0.9 kgf-m, 6.6 ft-lb) 

  15. Tighten the bolts holding the EGR cooler to the cylinder head RH.

    Tightening torque: 

    T2: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 12: Identifying EGR Cooler Bolts
    G10262139Courtesy of SUBARU OF AMERICA, INC.
  16. Connect the PCV hose (A) to intake manifold assembly.
  17. Connect the connector (B) to the manifold absolute pressure sensor.
  18. Connect the connector (C) to throttle body.
    Fig 13: Identifying Manifold Absolute Pressure Sensor Connector
    G10262115Courtesy of SUBARU OF AMERICA, INC.
  19. Connect the preheater hoses to the throttle body.
    Fig 14: Locating Preheater Hose Clamp
    G10262114Courtesy of SUBARU OF AMERICA, INC.
  20. Install the air intake boot. < Ref. to INSTALLATION , Air Intake Boot. >
  21. Connect the ground terminal to battery sensor. < Ref. to BATTERY , NOTE, Repair Contents. >
  22. Fill engine coolant. < Ref. to FILLING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant. >
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