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Home >> Subaru >> 2024 >> Crosstrek Base >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel Injection System >> Intake Manifold Assembly >> Removal >> 2.5 L Model
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2.5 L Model

NOTE: Components: Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>GENERAL DESCRIPTION>COMPONENT>INTAKE MANIFOLD ASSEMBLY .
  1. If the fuel delivery tube is disconnected after removing the intake manifold assembly, perform the following work.
    WARNING: Place "NO OPEN FLAMES" signs near the working area.
    CAUTION:
    • Be careful not to spill fuel  .
    • Catch the fuel from the pipes using a container or cloth  .
    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.
  2. Drain only the necessary amount of engine coolant. Ref. to COOLING (H4DO)>ENGINE COOLANT>REPLACEMENT>DRAINING OF ENGINE COOLANT .
    NOTE: This operation procedure would be possible by simply draining approximately 0.55 - 0.6 L (0.58 - 0.63 US qt, 0.48 - 0.53 Imp qt) of engine coolant.
  3. Remove the battery. Ref. to STARTING/CHARGING SYSTEMS (H4DO)>BATTERY>REMOVAL .
  4. Remove the air intake boot.
    1. Remove the clip.
    2. Loosen the clamp.
      G16760401Courtesy of SUBARU OF AMERICA, INC.
    3. 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.
    G16760402Courtesy 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), and disconnect the preheater hose (B).
    G16760403Courtesy of SUBARU OF AMERICA, INC.
  7. Disconnect the connector (A).
  8. Disconnect the evaporation hose (B), and remove the fuel delivery tube clamp (C).
  9. Disconnect the connector (D) and remove the clip (E).
  10. Remove the bolt securing the fuel pipe.
    G16760404Courtesy of SUBARU OF AMERICA, INC.
  11. Remove the nut (A) securing the EGR Cooler.
  12. Remove stud bolt (B) using TORX® E8.
  13. Loosen the bolt (C) holding the EGR cooler.
    G16760405Courtesy of SUBARU OF AMERICA, INC.
  14. Disconnect the terminal (A), connector (B) and connector (C), and remove the clip (D) and clip (E).
    G16760406Courtesy of SUBARU OF AMERICA, INC.
  15. Remove the connector (A) and connector (B).
    G16760407Courtesy of SUBARU OF AMERICA, INC.
  16. Disconnect the connector (A), and remove the clip (B) securing the engine wiring harness.
  17. Remove the clip (C) securing battery cable assembly and release the claw (D).
    G16760408Courtesy of SUBARU OF AMERICA, INC.
  18. Disconnect the connector (A).
  19. Use a pair of nippers to cut off the clip (B), and remove it from the intake manifold assembly.
    NOTE: Put alignment marks (a) on the clip and the engine wiring harness.
    G16760409Courtesy of SUBARU OF AMERICA, INC.
    G16760410Courtesy of SUBARU OF AMERICA, INC.
  20. Disconnect connector (A) from ECM. FIJI Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>ENGINE CONTROL MODULE (ECM)>REMOVAL 
  21. Disconnect the connector (B) from the main fuse box, and remove the engine wiring harness from the clip (C).
    NOTE: When disconnecting the connector (B), pry the portion (a) shown in the figure to release the lock using a flat tip screwdriver or similar tool wrapped with protective tape, and move the lever in the direction of arrow.
    G16760392Courtesy of SUBARU OF AMERICA, INC.
    G16760393Courtesy of SUBARU OF AMERICA, INC.
  22. Release the claw (A) securing the battery cable assembly to the bracket.
  23. Release the claw (B) securing the engine wiring harness to the bracket, and place it aside so that it does not interfere with work.
    G16760394Courtesy of SUBARU OF AMERICA, INC.
  24. Remove the fuel pipe protector No. 1.
    G16760414Courtesy of SUBARU OF AMERICA, INC.
  25. Remove the fuel delivery tube.
    G16760415Courtesy 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.
    G16760416Courtesy of SUBARU OF AMERICA, INC.
  27. Remove the cylinder head plate.
    NOTE: Perform this procedure only when required.
    G16760417Courtesy of SUBARU OF AMERICA, INC.
  28. Disconnect the fuel delivery pipe. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE C) .
    G16760418Courtesy of SUBARU OF AMERICA, INC.
  29. Disconnect the fuel delivery pipe (A). Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE B) .
  30. Disconnect the fuel delivery tube (B). Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE A) .
  31. Remove the clip (C) from the fuel pipe.
    G16760419Courtesy of SUBARU OF AMERICA, INC.
  32. When removing the fuel pipe protector No. 2
    1. Remove the camshaft position sensor (intake LH side). Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>CAMSHAFT POSITION SENSOR>REMOVAL>INTAKE>LH SIDE .
    2. Remove the fuel pipe protector No. 2.
    G16760420Courtesy of SUBARU OF AMERICA, INC.
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