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Home >> Subaru >> 2018 >> Forester 2.5i, Standard Trans >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Control/Fuel Injection System (H4DO) >> Intake Manifold Assembly >> Installation
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Intake Manifold Assembly: Installation

  1. Install the intake manifold assembly to the cylinder head together with the intake manifold protector No. 2 and the intake manifold protector No. 3.
    NOTE:
    • Use a new gasket.
    • Be careful not to let the engine wiring harness be caught by the parts.

    Tightening torque: 

    25 N.m (2. kgf-m, 18.4 ft-lb)

    G12505330Courtesy of SUBARU OF AMERICA, INC.
  2. Connect the fuel delivery tube and evaporation hose.
    1. Connect the evaporation hose to fuel pipe assembly.
      G12505331Courtesy 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 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 that the quick connector is securely connected.
      NOTE: Connect the quick connector as shown in the figure.
      G12505332Courtesy of SUBARU OF AMERICA, INC.
      G12505333Courtesy 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 that the quick connector is securely connected.
    NOTE: Connect the quick connector as shown in the figure.
    G12505334Courtesy 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.
    G12505335Courtesy of SUBARU OF AMERICA, INC.
  5. Install the engine wiring harness fixing clip to the intake manifold protector No. 3.
    G12505336Courtesy of SUBARU OF AMERICA, INC.
  6. Install the intake manifold protector No. 1 LH.

    Tightening torque: 

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

    G12505337Courtesy of SUBARU OF AMERICA, INC.
  7. Install the clip (A) securing the engine wiring harness to the intake manifold assembly, connect the connector (B) to the tumble generator valve, and connect the connector (C) to the fuel injector #3.
  8. 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 that the quick connector is securely connected.
    NOTE: Connect the quick connector as shown in the figure.
    G12505338Courtesy of SUBARU OF AMERICA, INC.
    G12505339Courtesy of SUBARU OF AMERICA, INC.
  9. Install the intake manifold protector No. 1 RH.

    Tightening torque: 

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

    G12505340Courtesy of SUBARU OF AMERICA, INC.
  10. Connect the connector to the EGR control valve.
    G12505341Courtesy of SUBARU OF AMERICA, INC.
  11. Install the air cleaner case (rear) together with the air cleaner element. Ref. to INTAKE (INDUCTION) (H4DO)>Air Cleaner Case>INSTALLATION .
  12. Secure the bulkhead wiring harness with clip (B) and connect the connector (A) to the mass air flow and intake air temperature sensor.
    G12505342Courtesy of SUBARU OF AMERICA, INC.
  13. Connect the connector (A) to the purge control solenoid valve.
  14. Install the preheater hose to the intake manifold.
    G12505343Courtesy of SUBARU OF AMERICA, INC.
  15. Connect the brake booster vacuum hose to the intake manifold.
    G12505344Courtesy of SUBARU OF AMERICA, INC.
  16. 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)

  17. 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 1: EGR Cooler Bolts (With Torque Specification)
    G12505345Courtesy of SUBARU OF AMERICA, INC.
  18. Connect the PCV hose (A) to intake manifold assembly.
  19. Connect the connector (B) to the manifold absolute pressure sensor.
  20. Connect the connector (C) to throttle body.
    G12505346Courtesy of SUBARU OF AMERICA, INC.
  21. Connect the preheater hoses to the throttle body.
    G12505347Courtesy of SUBARU OF AMERICA, INC.
  22. Install the air intake boot. Ref. to INTAKE (INDUCTION) (H4DO)>Air Intake Boot>INSTALLATION .
  23. Connect the ground terminal to battery sensor. Ref. to NOTE>NOTE>BATTERY .
  24. Fill engine coolant. Ref. to COOLING (H4DO)>Engine Coolant>REPLACEMENT>FILLING OF ENGINE COOLANT .
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