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Home >> Subaru >> 2004 >> Outback L.L. Bean Edition >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection (Fuel Systems) (H6DO) >> Intake Manifold >> Assembly

Intake Manifold: Assembly

  1. Install intake induction valve vacuum hose to intake manifold.
    Fig 1: Installing Intake Induction Valve Vacuum Hose
    G00897206Courtesy of SUBARU OF AMERICA, INC.
  2. Install fuel pipe and injector pipe assembly.

    Tightening torque: 

    1. 5.0 N.m (0.51 kgf-m, 3.7 ft-lb) 
    Fig 2: Installing Fuel Pipe And Injector Pipe Assembly
    G00897207Courtesy of SUBARU OF AMERICA, INC.
  3. Connect pressure regulator vacuum hose (A) to intake manifold.
    Fig 3: Connecting Pressure Regulator Vacuum Hose
    G00897208Courtesy of SUBARU OF AMERICA, INC.
  4. Install air assist and purge pipe assembly.

    Tightening torque: 

    1. 5.0 N.m (0.51 kgf-m, 3.7 ft-lb) 
    Fig 4: Installing Air Assist And Purge Pipe Assembly
    G00897209Courtesy of SUBARU OF AMERICA, INC.
  5. Install PCV pipe to intake manifold.

    Tightening torque: 

    1. 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 
    Fig 5: Installing PCV Pipe
    G00897210Courtesy of SUBARU OF AMERICA, INC.
  6. Install engine harness assembly to intake manifold.

    Tightening torque: 

    1. 5.0 N.m (0.51 kgf-m, 3.7 ft-lb) 
    Fig 6: Installing Engine Harness Assembly
    G00897211Courtesy of SUBARU OF AMERICA, INC.
  7. Install EGR valve.

    Tightening torque: 

    1. 19 N.m (1.9 kgf-m, 14 ft-lb) 
    NOTE: When removing EGR valve, use a new gasket.
  8. Connect connector to EGR valve.
    Fig 7: Connecting EGR Valve Connector
    G00897212Courtesy of SUBARU OF AMERICA, INC.
  9. Install purge control solenoid valve.

    Tightening torque: 

    1. 19 N.m (1.9 kgf-m, 14 ft-lb) 
  10. Connect connector to purge control solenoid valve.
    Fig 8: Connecting Purge Control Solenoid Valve Connector
    G00897213Courtesy of SUBARU OF AMERICA, INC.
  11. Connect hoses to purge control solenoid valve.
    CAUTION: Carefully connect the evaporation hoses.
    Fig 9: Connecting The Evaporation Hoses
    G00897214Courtesy of SUBARU OF AMERICA, INC.
  12. Install induction valve control solenoid.

    Tightening torque: 

    1. 19 N.m (1.9 kgf-m, 14 ft-lb) 
  13. Connect connector to induction valve control solenoid.
    Fig 10: Connecting Induction Valve Control Solenoid Connector
    G00897215Courtesy of SUBARU OF AMERICA, INC.
  14. Install induction valve.

    Tightening torque: 

    1. 19 N.m (1.9 kgf-m, 14 ft-lb) 
    Fig 11: Installing Induction Valve
    G00897216Courtesy of SUBARU OF AMERICA, INC.
  15. Connect hoses to induction valve control solenoid.
    CAUTION: Carefully connect the vacuum hoses.
    Fig 12: Connecting The Vacuum Hoses
    G00897217Courtesy of SUBARU OF AMERICA, INC.
  16. Install throttle body to intake manifold.
    NOTE: When removing throttle body, replace gasket with new one.

    Tightening torque: 

    1. 22 N.m (2.2 kgf-m, 15.9 ft-lb) 
    Fig 13: Installing Throttle Body
    G00897218Courtesy of SUBARU OF AMERICA, INC.
  17. Connect connectors to throttle position sensor.
    Fig 14: Connect Throttle Position Sensor Connectors
    G00897219Courtesy of SUBARU OF AMERICA, INC.
  18. Connect connectors to intake manifold pressure sensor (A) and idle air control solenoid valve (B).
  19. Connect air by-pass hose (C) to idle air control solenoid valve.
    Fig 15: Connecting Air By-Pass Hose
    G00897220Courtesy of SUBARU OF AMERICA, INC.
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