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Home >> Subaru >> 2002 >> Outback Limited, 4D Sedan >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection (Fuel Systems) (H4SO) >> Intake Manifold >> Assembly

Intake Manifold: Assembly

  1. Install fuel pipe assembly and pressure regulator, etc. to intake manifold.
  2. Tighten bolt which installs fuel pipes on intake manifold.
    1. Tightening torque:  4.9 N.m (0.5 kgf-m, 3.6 ft-lb)
    Fig 1: Tightening Fuel Pipes Bolt
    G02959657Courtesy of SUBARU OF AMERICA, INC.
  3. Connect right side fuel hose to injector pipe, and tighten clamp screw.
    Fig 2: Connecting Right Side Fuel Hose To Injector Pipe
    G02959658Courtesy of SUBARU OF AMERICA, INC.
  4. Install fuel injector pipe.
    Fig 3: Installing Fuel Injector Pipe
    G02959659Courtesy of SUBARU OF AMERICA, INC.
  5. Connect left side fuel hose to injector pipe, and tighten clamp screw.
    Fig 4: Connecting Left Side Fuel Hose To Injector Pipe
    G02959660Courtesy of SUBARU OF AMERICA, INC.
  6. Connect air assist hoses.
    Fig 5: Connecting Air Assist Hoses
    G02959661Courtesy of SUBARU OF AMERICA, INC.
  7. Install fuel injectors.
    NOTE: Always use new o-rings.
    Fig 6: Installing Fuel Injectors
    G02959662Courtesy of SUBARU OF AMERICA, INC.
    NOTE: Do not forget to install the fuel injector securing clip.
    Fig 7: Installing Fuel Injector Securing Clip
    G02959663Courtesy of SUBARU OF AMERICA, INC.
  8. Tighten bolt which installs injector pipe on intake manifold.
    1. Tightening torque:  5.0 N.m (0.51 kgf-m, 3.7 ft-lb)
    Fig 8: Installing Injector Pipe Bolt
    G02959664Courtesy of SUBARU OF AMERICA, INC.
  9. Tighten two bolts which install fuel pipes on the left side of intake manifold.
    1. Tightening torque:  5.0 N.m (0.51 kgf-m, 3.7 ft-lb)
    Fig 9: Tightening Fuel Pipes Bolt On Left Side Of Intake Manifold
    G02959665Courtesy of SUBARU OF AMERICA, INC.
  10. Tighten bolt which install injector pipe on intake manifold.
    1. Tightening torque:  5.0 N.m (0.51 kgf-m, 3.7 ft-lb)
    Fig 10: Tightening Injector Pipe Bolt On Intake Manifold
    G02959666Courtesy of SUBARU OF AMERICA, INC.
  11. Install purge control solenoid valve.
    Fig 11: Installing Purge Control Solenoid Valve
    G02959667Courtesy of SUBARU OF AMERICA, INC.
  12. Connect hoses to purge control solenoid valve.
    CAUTION: Carefully connect the evaporation hoses. 
    Fig 12: Connecting Hoses To Purge Control Solenoid Valve
    G02959668Courtesy of SUBARU OF AMERICA, INC.
  13. Install engine harness onto intake manifold.
  14. Connect connectors to fuel injectors and purge control solenoid valve.
  15. Hold engine harness by harness bands (*).
    Fig 13: Holding Engine Harness By Harness Bands
    G02959669Courtesy of SUBARU OF AMERICA, INC.
    NOTE: Do not use harness band on harnesses where they are supposed to be protected by the fuel pipe protector.
  16. Install fuel pipe protector RH.
    1. Tightening torque:  19 N.m (1.9 kgf-m, 13.7 ft-lb)
    Fig 14: Installing Fuel Pipe Protector RH
    G02959670Courtesy of SUBARU OF AMERICA, INC.
  17. Install fuel pipe protector LH.
    1. Tightening torque:  19 N.m (1.9 kgf-m, 13.7 ft-lb)
    Fig 15: Installing Fuel Pipe Protector LH (1 Of 2)
    G02959671Courtesy of SUBARU OF AMERICA, INC.
    Fig 16: Installing Fuel Pipe Protector LH (2 Of 2)
    G02959672Courtesy of SUBARU OF AMERICA, INC.
  18. Connect pressure regulator vacuum hose to intake manifold.
    Fig 17: Connecting Pressure Regulator Vacuum Hose To Intake Manifold
    G02959673Courtesy of SUBARU OF AMERICA, INC.
  19. Install air assist injector solenoid valve to bracket.
    1. Tightening torque:  5.0 N.m (0.51 kgf-m, 3.7 ft-lb)
    Fig 18: Installing Air Assist Injector Solenoid Valve To Bracket
    G02959674Courtesy of SUBARU OF AMERICA, INC.
  20. Connect air by-pass hoses to air assist solenoid valve.
    Fig 19: Connecting Air By-Pass Hoses To Air Assist Solenoid Valve
    G02959675Courtesy of SUBARU OF AMERICA, INC.
  21. Connect connector to air assist solenoid valve.
  22. Install throttle body to intake manifold.
    NOTE: Replace gasket with a new one.
    1. Tightening torque:  22 N.m (2.2 kgf-m, 15.9 ft-lb)
    Fig 20: Installing Throttle Body To Intake Manifold
    G02959676Courtesy of SUBARU OF AMERICA, INC.
  23. Connect connector to throttle position sensor and idle air control solenoid valve.
    Fig 21: Connecting Connector To Throttle Position Sensor & Idle Air Control Solenoid Valve
    G02959677Courtesy of SUBARU OF AMERICA, INC.
  24. Connect air by-pass hose to throttle body.
    Fig 22: Connecting Air By-Pass Hose To Throttle Body
    G02959678Courtesy of SUBARU OF AMERICA, INC.
  25. Install intake air temperature and pressure sensor.
    1. Tightening torque:  3.4 N.m (0.35 kgf-m, 2.5 ft-lb)
    Fig 23: Installing Intake Air Temperature & Pressure Sensor
    G02959679Courtesy of SUBARU OF AMERICA, INC.
    NOTE: Replace O-ring with a new one.
    Fig 24: Replacing O-Ring
    G02959680Courtesy of SUBARU OF AMERICA, INC.
  26. Connect connector to intake air temperature and pressure sensor.
  27. Install ignition coil and ignitor assembly.
    Fig 25: Installing Ignition Coil & Ignitor Assembly
    G02959681Courtesy of SUBARU OF AMERICA, INC.
  28. Connect connector to ignition coil and ignitor assembly.
  29. Install engine ground terminal to intake manifold.
Fig 26: Installing Engine Ground Terminal To Intake Manifold
G02959682Courtesy of SUBARU OF AMERICA, INC.
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