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Intake Manifold Assembly: Removal

  1. Release the fuel pressure. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL>PROCEDURE>RELEASING OF FUEL PRESSURE .
  2. Open the fuel filler lid and remove the fuel filler cap.
    NOTE: This operation is required to release the inner pressure of the fuel tank.
  3. Disconnect the ground terminal from battery sensor. Ref. to REPAIR CONTENTS>NOTE>BATTERY .
  4. Perform the steps below to remove the air intake boot, and place it aside so that it does not interfere with the work.
    CAUTION: Do not disconnect the PCV hose No. 2 (a).
    1. Remove the air cleaner case. Ref. to INTAKE (INDUCTION) (H4DO)>AIR CLEANER CASE>REMOVAL .
    2. Loosen the clamp, remove the air intake boot, and place it aside so that it does not interfere with the work.
      CAUTION: Be careful not to pull out the PCV hose No. 2 (a).
    G16523197Courtesy of SUBARU OF AMERICA, INC.
  5. Remove the PCV hose No. 1. Ref. to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DO)>PCV HOSE>REMOVAL>PCV HOSE NO. 1 .
  6. Disconnect the connector (A) from manifold absolute pressure sensor and remove the clip.
    G16523201Courtesy of SUBARU OF AMERICA, INC.
  7. When the engine coolant remains before removing the intake manifold assembly
    1. Remove the bolts securing the throttle body, and move the throttle body aside so that it does not interfere with the work.
    G16523202Courtesy of SUBARU OF AMERICA, INC.
  8. When the engine coolant has been drained before removing the intake manifold assembly
    1. Disconnect the connector (A) from the throttle body, and disconnect the preheater hose (B).
    G16523203Courtesy of SUBARU OF AMERICA, INC.
  9. Remove the fuel pipe protector RH No. 1. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL PIPE PROTECTOR>REMOVAL>FUEL PIPE PROTECTOR RH>FUEL PIPE PROTECTOR RH NO. 1 .
  10. Disconnect the connector (A) from the fuel injector (port injection side) RH and remove the clip.
    G16523204Courtesy of SUBARU OF AMERICA, INC.
  11. Remove the engine wiring harness from the engine rear hanger.
  12. Remove clip securing the battery cable assembly.
    G16523205Courtesy of SUBARU OF AMERICA, INC.
  13. Remove the bolt securing the brake vacuum pipe, and place it aside so that it does not interfere with the work.
    G16523206Courtesy of SUBARU OF AMERICA, INC.
  14. Remove the fuel pipe protector LH No. 1. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL PIPE PROTECTOR>REMOVAL>FUEL PIPE PROTECTOR LH>FUEL PIPE PROTECTOR LH NO. 1 .
  15. Disconnect the connector from the purge control solenoid valve.
    G16523207Courtesy of SUBARU OF AMERICA, INC.
  16. Use a pair of nippers to cut off the clip securing the engine wiring harness, and remove the clip from the intake manifold assembly.
    NOTE: Put alignment marks (a) on the clip and the engine wiring harness.
    G16523208Courtesy of SUBARU OF AMERICA, INC.
    G16523209Courtesy of SUBARU OF AMERICA, INC.
  17. Disconnect the evaporation hose (A).
  18. Open the claw on the fuel delivery tube clamp.
    G16523210Courtesy of SUBARU OF AMERICA, INC.
  19. Disconnect the fuel delivery tube (cylinder direct injection side) (A). Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE A) .
  20. Disconnect the fuel delivery tube (port injection side) (B). Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE A) .
  21. Disconnect the fuel delivery pipe assembly (C). Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE C) .
  22. Remove the fuel delivery pipe assembly.
    NOTE: Perform this procedure only when required.
    G16523211Courtesy of SUBARU OF AMERICA, INC.
  23. Disconnect the connector (A) from the fuel injector (port injection side) LH.
  24. Disconnect the connector (B) from high-pressure fuel pump.
    G16523212Courtesy of SUBARU OF AMERICA, INC.
  25. Move the A/C compressor aside so that it does not interfere with the work.
    1. Remove the V-belts. Ref. to MECHANICAL (H4DO)>V-BELT>REMOVAL>V-BELT .
    2. Disconnect the connector.
      G16523213Courtesy of SUBARU OF AMERICA, INC.
    3. Remove the bolt securing the A/C compressor.
      G16523214Courtesy of SUBARU OF AMERICA, INC.
    4. Move the A/C compressor as shown in the figure.
      CAUTION:
      • Do not bend the pipe portion of the hose pressure discharge and the hose pressure suction.
      • Be careful not to drop the A/C compressor.
      • Be careful not to damage the adjacent parts with the A/C compressor.
    G16523215Courtesy of SUBARU OF AMERICA, INC.
  26. Remove the intake manifold assembly.
CAUTION: Remove the intake manifold assembly so that it is not damaged by adjacent parts.
G16523216Courtesy of SUBARU OF AMERICA, INC.
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