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Home >> Subaru >> 2017 >> Forester 2.5i, Eng CD FB25BA, Standard Trans >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection System (H4DO) >> Intake Manifold Assembly >> Installation

Intake Manifold Assembly: Installation

  1. Install the intake manifold assembly to the cylinder head together with the intake manifold protector No. 2 and the intake manifold protector No. 3.
    NOTE:
    • Use a new gasket.
    • Be careful not to let the engine harness be caught by the parts.

    Tightening torque: 

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

    Fig 1: Locating Intake Manifold Assembly Bolts
    G11263302Courtesy of SUBARU OF AMERICA, INC.
  2. Connect the fuel delivery tube and evaporation hose.
    1. Connect the evaporation hose to fuel pipe assembly.
      Fig 2: Locating Evaporation Hose To Fuel Pipe Assembly
      G11263301Courtesy of SUBARU OF AMERICA, INC.
    2. Connect the quick connector on the fuel delivery tube to the fuel pipe assembly, and fix the fuel delivery tube using clip (A).
      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 that the quick connector is securely connected.
      NOTE: Connect the quick connector as shown in the figure.
      Fig 3: Connecting Quick Connector
      G11263305Courtesy of SUBARU OF AMERICA, INC.
      Fig 4: Locating Quick Connector
      G11263300Courtesy of SUBARU OF AMERICA, INC.
  3. Connect the fuel delivery pipe to the fuel pipe LH.
    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 that the quick connector is securely connected.
    NOTE: Connect the quick connector as shown in the figure.
    Fig 5: Connecting Quick Connector
    G11263307Courtesy of SUBARU OF AMERICA, INC.
  4. Connect the connector (A) to the tumble generator valve, and connect the connector (B) to the fuel injector #4.
    Fig 6: Locating Quick Connector
    G11263298Courtesy of SUBARU OF AMERICA, INC.
  5. Install the engine harness fixing clip to the intake manifold protector No. 3.
    Fig 7: Locating Engine Harness Fixing Clip To Intake Manifold Protector No. 3
    G11263296Courtesy of SUBARU OF AMERICA, INC.
  6. Install the intake manifold protector No. 1 LH.

    Tightening torque: 

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

    Fig 8: Locating Intake Manifold Protector No. 1 LH With Bolts
    G11263295Courtesy of SUBARU OF AMERICA, INC.
  7. Install the clip (A) securing the engine harness to the intake manifold assembly, and connect the connector (B) to the tumble generator valve and connect the connector (C) to the fuel injector #3.
  8. 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 that the quick connector is securely connected.
    NOTE: Connect the quick connector as shown in the figure.
    Fig 9: Connecting Quick Connector
    G11263311Courtesy of SUBARU OF AMERICA, INC.
    Fig 10: Locating Quick Connector
    G11263294Courtesy of SUBARU OF AMERICA, INC.
  9. Install the intake manifold protector No. 1 RH.

    Tightening torque: 

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

    Fig 11: Locating Intake Manifold Protector No. 1 RH With Bolts
    G10262120Courtesy of SUBARU OF AMERICA, INC.
  10. Connect the connector to the EGR control valve.
    Fig 12: Locating Connector To EGR Control Valve
    G11263291Courtesy of SUBARU OF AMERICA, INC.
  11. Install the air cleaner case (rear) together with the air cleaner element. Ref. to INTAKE (INDUCTION) (H4DO)>Air Cleaner Case>INSTALLATION .
  12. Secure the bulkhead wiring harness with clip (B) and connect the connector (A) to the mass air flow and intake air temperature sensor.
    Fig 13: Identifying Bulkhead Wiring Harness With Clip
    G11263315Courtesy of SUBARU OF AMERICA, INC.
  13. Connect the connector (A) to the purge control solenoid valve.
  14. Install the preheater hose to the intake manifold.
    Fig 14: Connecting Connector To Purge Control Solenoid Valve
    G11263289Courtesy of SUBARU OF AMERICA, INC.
  15. Connect the brake booster vacuum hose to the intake manifold.
    Fig 15: Locating Brake Booster Vacuum Hose To Intake Manifold
    G11263288Courtesy of SUBARU OF AMERICA, INC.
  16. Tighten the bolt securing the EGR cooler to the EGR control valve.
    NOTE: Use a new gasket.

    Tightening torque: 

    T1: 9 N.m (0.9 kgf-m, 6.6 ft-lb)

  17. Tighten the bolts holding the EGR cooler to the cylinder head RH.

    Tightening torque: 

    T2: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

    Fig 16: Identifying EGR Cooler To Cylinder Head RH With Bolts
    G11263318Courtesy of SUBARU OF AMERICA, INC.
  18. Connect the PCV hose (A) to intake manifold assembly.
  19. Connect the connector (B) to the manifold absolute pressure sensor.
  20. Connect the connector (C) to throttle body.
    Fig 17: Connecting PCV Hose To Intake Manifold Assembly
    G11263286Courtesy of SUBARU OF AMERICA, INC.
  21. Connect the preheater hoses to the throttle body.
    Fig 18: Locating Preheater Hoses To Throttle Body
    G10262114Courtesy of SUBARU OF AMERICA, INC.
  22. Install the air intake boot. Ref. to INTAKE (INDUCTION) (H4DO)>Air Intake Boot>INSTALLATION .
  23. Connect the ground terminal to battery sensor. Ref. to NOTE>NOTE>BATTERY .
  24. Fill engine coolant. Ref. to COOLING(H4DO)>Engine Coolant>REPLACEMENT>FILLING OF ENGINE COOLANT .
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