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Home >> Subaru >> 2016 >> Crosstrek Hybrid >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection System (Hybrid) >> Intake Manifold >> Installation

Intake Manifold: Installation

  1. Connect the connector (A) to the EGR control valve, and connect the brake vacuum hose (B) to the intake manifold.
    Fig 1: Connecting Connector To EGR Control Valve
    G09487077Courtesy of SUBARU OF AMERICA, INC.
  2. Install the intake manifold to the tumble generator valve assembly.
    NOTE: Use a new gasket.

    Tightening torque: 

    8.3 N.m (0.8 kgf-m, 6.1 ft-lb) 

    Fig 2: Locating Intake Manifold Bolts
    G09487076Courtesy of SUBARU OF AMERICA, INC.
  3. Connect the fuel delivery tube and evaporation hose.
    1. Connect the evaporation hose (C) to the fuel pipe assembly.
    2. Connect the quick connector (A) of the fuel delivery tube to the fuel pipe assembly, and secure the fuel delivery tube using clip (B).
      CAUTION:
      • Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.
      • When connecting the quick connector, make sure to insert it all the way in before locking the slider.
      • When it is difficult to lock the slider, check that the connector is fully inserted.
      • After locking the slider, check again that the quick connector is securely connected.
      NOTE: Connect the quick connector as shown in the figure.
      Fig 3: Connecting Quick Connector
      G10320526Courtesy of SUBARU OF AMERICA, INC.
      Fig 4: Disconnecting Evaporation Hose From Fuel Pipe Assembly
      G09486118Courtesy of SUBARU OF AMERICA, INC.
  4. Connect the fuel delivery pipe to the fuel pipe RH.
    CAUTION:
    • Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.
    • When connecting the quick connector, make sure to insert it all the way in before locking the slider.
    • When it is difficult to lock the slider, check that the connector is fully inserted.
    • After locking the slider, check again that the quick connector is securely connected.
    NOTE: Connect the quick connector as shown in the figure.
    Fig 5: Connecting Quick Connector
    G10320528Courtesy of SUBARU OF AMERICA, INC.
    Fig 6: Locating Quick Connector
    G09487073Courtesy of SUBARU OF AMERICA, INC.
  5. Install the intake manifold protector RH.

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 7: Locating Intake Manifold Protector RH Bolts
    G09487071Courtesy of SUBARU OF AMERICA, INC.
  6. Connect the fuel delivery pipe to the fuel pipe LH in the same manner, and install the intake manifold protector LH.
  7. Tighten the bolt securing the EGR cooler to the EGR control valve.
    NOTE: Use a new gasket

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 8: Locating Bolts And EGR Cooler To EGR Control Valve
    G09487070Courtesy of SUBARU OF AMERICA, INC.
  8. Install the purge control solenoid valve. < Ref. to INSTALLATION , Purge Control Solenoid Valve. >
  9. Connect the connector (A) to ISG.
  10. Connect the connector (B) to the manifold absolute pressure sensor.
  11. Install the PCV hose (C) to the PCV valve.
    Fig 9: Connecting Connector To ISG
    G10320515Courtesy of SUBARU OF AMERICA, INC.
  12. Connect the connector (A) to the throttle position sensor.
  13. Connect the preheater hoses (B) to the throttle body.
  14. Connect the preheater hose (C) to the water pipe assembly LH.
    Fig 10: Connecting Connector To Throttle Position Sensor
    G09487068Courtesy of SUBARU OF AMERICA, INC.
  15. Install the air intake boot No. 2. < Ref. to AIR INTAKE BOOT NO. 2 , INSTALLATION, Air Intake Boot. >
  16. Install the air cleaner case. < Ref. to INSTALLATION , Air Cleaner Case. >
  17. Lift up the vehicle.
  18. Install the under cover. < Ref. to INSTALLATION , Front Under Cover. >
  19. Lower the vehicle.
  20. Install the collector cover.
  21. Connect the battery ground terminal. < Ref. to BATTERY , NOTE, Note. >
  22. Fill engine coolant. < Ref. to FILLING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant. >
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