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Home >> Subaru >> 2004 >> Baja Turbo, Automatic >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection (Fuel Systems) (H4DOTC) >> Intake Manifold >> Assembly
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Intake Manifold: Assembly

NOTE: Replace the gasket with a new one.
  1. Install the tumble generator valve assembly to the intake manifold.

    Tightening torque: 

    8.25 N.m (0.84 kgf-m, 6.1 ft-lb) 

    Fig 1: Installing Tumble Generator Valve Assembly To Intake Manifold
    G00928795Courtesy of SUBARU OF AMERICA, INC.
  2. Install the air intake duct to the intake manifold.

    Tightening torque: 

    19 N.m (1.94 kgf-m, 13.7 ft-lb) 

    Fig 2: Installing Air Intake Duct To Intake Manifold
    G00928796Courtesy of SUBARU OF AMERICA, INC.
  3. Install the fuel pipe assembly and pressure regulator to the intake manifold.

    Tightening torque: 

    4.9 N.m (0.5 kgf-m, 3.6 ft-lb) 

    Fig 3: Installing Fuel Pipe Assembly
    G00928797Courtesy of SUBARU OF AMERICA, INC.
  4. Install the fuel injector pipe LH.
  5. Connect the left side fuel hose to injector pipe, and tighten the clamp screw.
    Fig 4: Installing Fuel Injector Pipe LH
    G00928798Courtesy of SUBARU OF AMERICA, INC.
  6. Install the fuel injector pipe RH.
  7. Connect the right side fuel hose to injector pipe, and tighten the clamp screw.
    Fig 5: Installing Fuel Injector Pipe RH
    G00928799Courtesy of SUBARU OF AMERICA, INC.
  8. Install the engine harness to the intake manifold.
  9. Install the harness bracket which holds the engine harness onto intake manifold.

    Tightening torque: 

    19 N.m (1.94 kgf-m, 13.7 ft-lb) 

    Fig 6: Installing Fuel Injector Pipe Onto Intake Manifold
    G00928800Courtesy of SUBARU OF AMERICA, INC.
  10. Tighten the bolts which install the fuel injector pipe onto intake manifold.

    Tightening torque: 

    19 N.m (1.94 kgf-m, 13.7 ft-lb) 

    • LH SIDE
      Fig 7: Tightening Bolts LH Side (1 Of 2)
      G00928801Courtesy of SUBARU OF AMERICA, INC.
      Fig 8: Tightening Bolts LH Side (2 Of 2)
      G00928802Courtesy of SUBARU OF AMERICA, INC.
    • RH SIDE
      Fig 9: Tightening Bolts RH Side (1 Of 2)
      G00928803Courtesy of SUBARU OF AMERICA, INC.
      Fig 10: Tightening Bolts RH Side (2 Of 2)
      G00928804Courtesy of SUBARU OF AMERICA, INC.
  11. Tighten the two bolts which install the fuel pipes on the left side of intake manifold.

    Tightening torque: 

    5 N.m (0.5 kgf-m, 3.6 ft-lb) 

    Fig 11: Tightening Two Bolts Which Installing Fuel Pipes On Left Side Of Intake Manifold
    G00928805Courtesy of SUBARU OF AMERICA, INC.
  12. Connect the evaporation hoses to the purge valve.
    NOTE: Connect the evaporation hoses as shown in the figure.
    Fig 12: Connecting Evaporation Hoses To Purge Valve
    G00928806Courtesy of SUBARU OF AMERICA, INC.
  13. Connect the evaporation hose and purge valve to the intake manifold.
    Fig 13: Connecting Evaporation Hose & Purge Valve To The Intake Manifold
    G00928807Courtesy of SUBARU OF AMERICA, INC.
  14. Install the purge control solenoid valve.

    Tightening torque: 

    16 N.m (1.6 kgf-m, 11.8 ft-lb) 

    Fig 14: Installing Purge Control Solenoid Valve
    G00928808Courtesy of SUBARU OF AMERICA, INC.
  15. Connect the hoses to the purge control solenoid valve.
    NOTE: Connect the evaporation hoses as shown in the figure.
    Fig 15: Connecting Hoses To Purge Control Solenoid Valve
    G00928809Courtesy of SUBARU OF AMERICA, INC.
  16. Connect the connector to the purge control solenoid valve.
  17. Connect the connector to the tumble generator valve sensor.
    Fig 16: Connecting Connector To Tumble Generator Valve Sensor
    G00928810Courtesy of SUBARU OF AMERICA, INC.
  18. Connect the connector to the tumble generator valve actuator.
    Fig 17: Connecting Connector To Tumble Generator Valve Actuator
    G00928811Courtesy of SUBARU OF AMERICA, INC.
  19. Connect the connector to the fuel injector.
    Fig 18: Connecting Connector To Fuel Injector
    G00928812Courtesy of SUBARU OF AMERICA, INC.
  20. Install the throttle body to the intake manifold.
    NOTE: Replace the gasket with a new one.

    Tightening torque: 

    8 N.m (0.8 kgf-m, 5.8 ft-lb) 

    Fig 19: Installing Throttle Body To Intake Manifold
    G00928813Courtesy of SUBARU OF AMERICA, INC.
  21. Connect the connector to the throttle position sensor (A) and manifold absolute pressure sensor (B).
    Fig 20: Connecting Connector
    G00928814Courtesy of SUBARU OF AMERICA, INC.
  22. Install the engine ground terminal to the intake manifold.

    Tightening torque: 

    19 N.m (1.94 kgf-m, 13.7 ft-lb) 

    Fig 21: Installing Engine Ground Terminal (1 Of 2)
    G00928815Courtesy of SUBARU OF AMERICA, INC.
    Fig 22: Installing Engine Ground Terminal (2 Of 2)
    G00928816Courtesy of SUBARU OF AMERICA, INC.