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

Intake Manifold: Removal

  1. Set the vehicle on a lift.
  2. Remove the V-belt covers.
    Fig 1: Locating V-Belt Covers
    G06344549Courtesy of SUBARU OF AMERICA, INC.
  3. Collect the refrigerant from A/C system. Ref. to PROCEDURE , Refrigerant Recovery Procedure.
  4. Release the fuel pressure. Ref. to RELEASING OF FUEL PRESSURE , PROCEDURE, Fuel.
  5. Disconnect the ground cable from battery.
    Fig 2: Identifying Battery Ground Cable
    G05019586Courtesy of SUBARU OF AMERICA, INC.
  6. Open the fuel filler lid and remove the fuel filler cap.
  7. Lift up the vehicle.
  8. Remove the under cover.
  9. Drain approximately 3.0 l  (3.2 US qt, 2.6 lmp qt) of coolant. Ref. to DRAINING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant.
  10. Remove the air intake duct. Ref. to REMOVAL , Air Intake Duct.
  11. Remove the air intake boot.
    Fig 3: Locating Air Intake Boot
    G06344551Courtesy of SUBARU OF AMERICA, INC.
  12. Remove the intercooler. Ref. to REMOVAL , Intercooler.
  13. Remove the generator. Ref. to REMOVAL , Generator.
  14. Remove the coolant filler tank. Ref. to REMOVAL , Coolant Filler Tank.
  15. Disconnect the A/C pressure hoses from A/C compressor. Ref. to REMOVAL , Hose and Pipe.
  16. Disconnect the vacuum hose (A) from the PCV hose assembly and the PCV hose assembly connector (B) from the intake duct.
    Fig 4: Identifying Vacuum Hose
    G06344552Courtesy of SUBARU OF AMERICA, INC.
  17. Disconnect the engine coolant hose from throttle body.
    Fig 5: Locating Engine Coolant Hose
    G06344553Courtesy of SUBARU OF AMERICA, INC.
  18. Disconnect the brake booster vacuum hose (A) and pressure regulator vacuum hose (B) from the intake manifold.
    Fig 6: Identifying Brake Booster Vacuum Hose And Pressure Regulator Vacuum Hose
    G06344554Courtesy of SUBARU OF AMERICA, INC.
  19. Disconnect the air control hose (A) from the waste gate actuator, and loosen the clamp which holds the intake duct to the turbocharger.
    Fig 7: Locating Air Control Hose
    G06344555Courtesy of SUBARU OF AMERICA, INC.
  20. Disconnect the bulkhead harness connectors from the engine harness connectors.
    Fig 8: Identifying Engine Harness Connectors
    G05954730Courtesy of SUBARU OF AMERICA, INC.
  21. Remove the engine harness connector from the engine harness bracket.
    Fig 9: Locating Engine Harness Connector
    G06344557Courtesy of SUBARU OF AMERICA, INC.
  22. Disconnect the connectors from the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).
    Fig 10: Identifying Engine Coolant Temperature Sensor, Oil Pressure Switch And Crankshaft Position Sensor Connectors
    G06344558Courtesy of SUBARU OF AMERICA, INC.
  23. Disconnect the connector from power steering pump switch.
    Fig 11: Identifying Power Steering Pump Switch Connector
    G05340076Courtesy of SUBARU OF AMERICA, INC.
  24. Disconnect the knock sensor connector.
    Fig 12: Locating Knock Sensor Connector
    G06344560Courtesy of SUBARU OF AMERICA, INC.
  25. Disconnect the connector from the secondary air combination valve.
    Fig 13: Locating Secondary Air Combination Valve Connector
    G06344561Courtesy of SUBARU OF AMERICA, INC.
  26. Disconnect the connector from the intake camshaft position sensor.
    Fig 14: Locating Intake Camshaft Position Sensor Connector
    G06344562Courtesy of SUBARU OF AMERICA, INC.
  27. Disconnect the connector from the intake oil flow control solenoid valve.
    Fig 15: Locating Intake Oil Flow Control Solenoid Valve Connector
    G06344563Courtesy of SUBARU OF AMERICA, INC.
  28. Lift up the vehicle.
  29. Remove the engine harness cover, (right side only.)
    Fig 16: Identifying Engine Harness Cover And Bolt
    G06344564Courtesy of SUBARU OF AMERICA, INC.
  30. Disconnect the connectors from the exhaust camshaft position sensor (A), exhaust oil flow control solenoid valve (B), and ignition coil (C).
    Fig 17: Identifying Exhaust Camshaft Position Sensor, Exhaust Oil Flow Control Solenoid Valve And Ignition Coil Connectors
    G06344565Courtesy of SUBARU OF AMERICA, INC.
  31. Lower the vehicle.
  32. Remove the clip (A) which hold the engine harness to the rocker cover RH.
    Fig 18: Identifying Engine Harness To Rocker Cover RH With Clips
    G06344566Courtesy of SUBARU OF AMERICA, INC.
  33. Remove the bolts that secure the air duct to the rocker cover LH, and remove the engine harness.
    Fig 19: Locating Air Duct To Rocker Cover LH And Bolts
    G06344567Courtesy of SUBARU OF AMERICA, INC.
  34. Disconnect the fuel delivery hose, fuel return hose and evaporation hose.
    1. Set the ST to the fuel pipe.

      ST 42099AE000 QUICK CONNECTOR RELEASE

    2. Disconnect the quick connector of the fuel delivery hose and fuel return hose by pushing the ST in the direction of the arrow.
    3. Remove the clip and disconnect the evaporation hose from the fuel pipe.
      CAUTION:
      • Be careful not to spill fuel.
      • Catch the fuel from hoses using a container or cloth.
        Fig 20: Disconnecting Quick Connector Of Fuel Delivery Hose And Fuel Return Hose
        G06344568Courtesy of SUBARU OF AMERICA, INC.
  35. Remove the intake manifold from cylinder head.
    Fig 21: Locating Intake Manifold
    G06344569Courtesy of SUBARU OF AMERICA, INC.
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