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Home >> Subaru >> 2009 >> Impreza WRX STi >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection System (STI) >> Intake Manifold >> Assembly

Intake Manifold: Assembly

  1. Install the tumble generator valve assembly onto intake manifold.
    NOTE: Use a new gasket.

    Tightening torque: 8.25 N.m (0.8 kgf-m, 6.1 ft-lb) 

    Fig 1: Locating Tumble Generator Assembly
    G06344612Courtesy of SUBARU OF AMERICA, INC.
  2. Install the air intake duct to the intake manifold.

    Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb) 

    Fig 2: Locating Intake Duct
    G06344611Courtesy of SUBARU OF AMERICA, INC.
  3. Install the fuel pipe assembly to the intake manifold.

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

    Fig 3: Locating Fuel Pipe Assembly To Intake Manifold And Bolts
    G05333518Courtesy of SUBARU OF AMERICA, INC.
  4. Install the fuel injector pipe LH and connect the LH side fuel hose to the fuel injector pipe LH, and secure with a clamp.

    Tightening torque: 1.25 N.m (0.1 kgf-m, 0.9 ft-lb) 

    Fig 4: Identifying Fuel Injector Pipe LH And Clamp
    G06344609Courtesy of SUBARU OF AMERICA, INC.
  5. Install the fuel injector pipe RH and connect the RH side fuel hose to the fuel injector pipe RH, and secure with a clamp.

    Tightening torque: 1.25 N.m (0.1 kgf-m, 0.9 ft-lb) 

    Fig 5: Identifying Fuel Injector Pipe RH And Clamp
    G06344608Courtesy of SUBARU OF AMERICA, INC.
  6. Install the engine harness to the intake manifold and attach the harness brackets holding the engine harness.

    Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb) 

    Fig 6: Locating Engine Harness To Intake Manifold And Bolts
    G06344607Courtesy of SUBARU OF AMERICA, INC.
  7. Install the fuel injector.
    Fig 7: Removing Fuel Injector
    G06344606Courtesy of SUBARU OF AMERICA, INC.
  8. Install the bolts which hold fuel injector pipe.
    • RH side

      Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb) 

      Fig 8: Locating Fuel Injector Pipe And Bolts (RH)
      G06344603Courtesy of SUBARU OF AMERICA, INC.
    • LH side

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

      Fig 9: Locating Fuel Injector Pipe And Bolts (LH) (1 Of 2)
      G06344604Courtesy of SUBARU OF AMERICA, INC.

      Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb) 

      Fig 10: Locating Fuel Injector Pipe And Bolts (LH) (2 Of 2)
      G06344605Courtesy of SUBARU OF AMERICA, INC.
  9. Connect the connector to the tumble generator valve assembly.
    Fig 11: Identifying Tumble Generator Valve Assembly Connector
    G06344602Courtesy of SUBARU OF AMERICA, INC.
  10. Connect the connectors to the fuel injector.
    Fig 12: Locating Fuel Injector Connector
    G06344601Courtesy of SUBARU OF AMERICA, INC.
  11. Secure the engine harness to the fuel injector pipe with the harness band (A).
    • RH side
      Fig 13: Identifying Harness Band (RH Side)
      G06344599Courtesy of SUBARU OF AMERICA, INC.
    • LH side
      Fig 14: Identifying Harness Band (LH Side)
      G06344600Courtesy of SUBARU OF AMERICA, INC.
  12. Install the throttle body to the intake manifold.
    NOTE: Use a new gasket.

    Tightening torque: 8 N.m (0.8 kgf-m, 5.9 ft-lb) 

    Fig 15: Locating Throttle Body And Bolts
    G06344598Courtesy of SUBARU OF AMERICA, INC.
  13. Secure the engine harness and vacuum hose using the clip (A), and secure the engine harness to the engine harness stay using the clip (B), and install the bolt which holds the engine harness to the intake manifold.

    Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb) 

    Fig 16: Locating Engine Harness And Vacuum Hose Clips And Bolt
    G06344597Courtesy of SUBARU OF AMERICA, INC.
  14. Connect the connectors to the throttle position sensor (A) and manifold pressure sensor (B).
    Fig 17: Identifying Throttle Position Sensor Connector And Manifold Pressure Sensor Connector
    G06344596Courtesy of SUBARU OF AMERICA, INC.
  15. Install the engine ground terminal to intake manifold.

    Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb) 

    Fig 18: Locating Engine Ground Terminals
    G06344595Courtesy of SUBARU OF AMERICA, INC.
  16. Install the solenoid valve bracket together with the wastegate control solenoid valve.

    Tightening torque: 

    T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    T2: 19 N.m (1.9 kgf-m, 14.0 ft-lb) 

    Fig 19: Installing Solenoid Valve Bracket Together With Wastegate Control Solenoid Valve
    G06344631Courtesy of SUBARU OF AMERICA, INC.
  17. Install purge control solenoid valve 1 and purge control solenoid valve 2.
    NOTE: Connect the evaporation hose as shown in the figure.
    Fig 20: Identifying Purge Control Solenoid Valve 1 And Purge Control Solenoid Valve 2
    G06344632Courtesy of SUBARU OF AMERICA, INC.

    Tightening torque: 

    T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    T2: 19 N.m (1.9 kgf-m, 14.0 ft-lb) 

    Fig 21: Identifying Evaporation Hose And Bolts
    G06344633Courtesy of SUBARU OF AMERICA, INC.
  18. Install the connector to the intake duct.
    Fig 22: Removing Intake Duct And Connector
    G06344592Courtesy of SUBARU OF AMERICA, INC.
  19. Install the fuel pipe protector LH.

    Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb) 

    Fig 23: Locating Fuel Pipe Protector LH
    G06344591Courtesy of SUBARU OF AMERICA, INC.
  20. Install the fuel pipe protector RH, and secure the engine harness to the fuel pipe protector RH using the clip (A).

    Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb) 

    Fig 24: Locating Fuel Pipe Protector RH And Clamp
    G06344590Courtesy of SUBARU OF AMERICA, INC.