Intake Manifold: Assembly

1. Apply liquid gasket to the nipple threads, and install the nipple to the intake manifold.

   Liquid gasket: 

   THREE BOND 1105 (Part No. 004403010) 

   Tightening torque: 

   T1: 17 N.m (1.7 kgf-m, 12.5 ft-lb) 

   T2: 25 N.m (2.5 kgf-m, 18.4 ft-lb) 

   Fig 1: Identifying Nipple Threads Liquid Gasket Applying Area

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2. 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 2: Locating Tumble Generator Valve Assembly Mounting Bolts

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3. Install the air intake duct to the intake manifold.

   Tightening torque: 

   17 N.m (1.7 kgf-m, 12.5 ft-lb) 

   Fig 3: Locating Intake Duct

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4. Install the fuel pipe assembly to the intake manifold.

   Tightening torque: 

   6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

   Fig 4: Locating Fuel Pipe Assembly Mounting Bolts

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5. Install the fuel injector pipe LH and connect the LH side fuel hose to the fuel injector pipe LH. < Refer to CONNECTING FUEL DELIVERY HOSE, FUEL RETURN HOSE AND FUEL HOSE , INSTALLATION, Fuel Delivery, Return and Evaporation Lines. >
   Fig 5: Locating Side Fuel Hose Clamp

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6. Install the fuel injector pipe RH and connect the RH side fuel hose to the fuel injector pipe RH. < Refer to CONNECTING FUEL DELIVERY HOSE, FUEL RETURN HOSE AND FUEL HOSE , INSTALLATION, Fuel Delivery, Return and Evaporation Lines. >
   Fig 6: Locating Side Fuel Hose Clamp

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7. 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 7: Locating Engine Harness Bracket Bolts

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8. Install the fuel injector.
   NOTE: Use new O-rings.
   Fig 8: Installing Fuel Injector

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9. Install the bolts which hold fuel injector pipe.
   • RH side

     Tightening torque: 

     19 N.m (1.9 kgf-m, 14.0 ft-lb) 

     Fig 9: Locating Fuel Injector Pipe Mounting Bolts

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   • LH side

     Tightening torque: 

     6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

     Fig 10: Locating Fuel Injector Pipe Mounting Bolts

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     Tightening torque: 

     19 N.m (1.9 kgf-m, 14.0 ft-lb) 

     Fig 11: Locating Fuel Injector Pipe Mounting Bolts

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10. Connect the connector to the tumble generator valve assembly.
    Fig 12: Locating Tumble Generator Valve Assembly Connector

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11. Connect the connectors to the fuel injector.
    Fig 13: Locating Fuel Injector Connector

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12. Secure the engine harness to the fuel injector pipe with the harness band (A).
    • RH side
      Fig 14: Identifying Engine Harness Band

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    • LH side
      Fig 15: Identifying Engine Harness Band

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13. 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 16: Locating Intake Manifold And Mounting Bolts

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14. 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 17: Identifying Engine Harness Stay Clips And Bolt

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15. Connect connector (A) to the throttle position sensor and connector (B) to the manifold pressure sensor.
    Fig 18: Identifying Throttle Position Sensor And Manifold Pressure Sensor Connector

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16. Install the engine ground terminal to intake manifold.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14.0 ft-lb) 

    Fig 19: Locating Engine Ground Terminals Mounting Bolt

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17. 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 20: Identifying Solenoid Valve Bracket And Mounting Bolts

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18. Connect the vacuum hose (B) to the intake duct, then connect the connector (A) to the wastegate control solenoid valve.
    Fig 21: Identifying Intake Duct Vacuum Hose

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19. Install purge control solenoid valve 1 and purge control solenoid valve 2.
    NOTE: Connect the vacuum hose and vacuum control hose as shown in the figure.
    Fig 22: Identifying Vacuum Hose And Vacuum Control Hose Installation Position

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    Tightening torque: 

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

    T2: 16 N.m (1.6 kgf-m, 11.8 ft-lb) 

    Fig 23: Identifying Purge Control Solenoid Valve Mounting Bolts

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20. Attach the connector to the PCV hose assembly.
    Fig 24: Identifying PCV Hose Assembly Connector

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21. Install the connector to the intake duct.
    Fig 25: Locating Intake Duct Connector

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22. Install the fuel pipe protector LH.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14.0 ft-lb) 

    Fig 26: Locating Fuel Pipe Protector Mounting Bolts

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23. 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 27: Locating Fuel Pipe Protector Clamp

Courtesy of SUBARU OF AMERICA, INC.