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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 >> Removal
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Intake Manifold: Removal

  1. Release the fuel pressure. Refer to FUEL .
  2. Open the fuel filler lid and remove the fuel filler cap.
  3. Disconnect the ground cable from battery.
    Fig 1: Disconnecting Ground Cable From Battery
    G00928737Courtesy of SUBARU OF AMERICA, INC.
  4. Lift up the vehicle.
  5. Remove the under cover.
  6. Drain the engine coolant about 3.0 (3.2 US qt, 2.6 Imp qt).
    Fig 2: Removing Under Cover
    G00928738Courtesy of SUBARU OF AMERICA, INC.
  7. Remove the air cleaner upper cover and air intake boot. Refer to REMOVAL , Air Cleaner.
  8. Remove the air cleaner element.
  9. Remove the intercooler. Refer to REMOVAL , Intercooler.
  10. Remove the coolant filler tank. Refer to REMOVAL , Coolant Filler Tank.
  11. Remove the power steering pump.
    1. Remove the front side V-belt. Refer to REMOVAL , V-belt.
    2. Disconnect the power steering switch connector.
      Fig 3: Removing Power Steering Switch Connector
      G00928739Courtesy of SUBARU OF AMERICA, INC.
    3. Remove the bolts which secure the power steering pipe brackets to the intake manifold.
      NOTE: Do not disconnect the power steering hose.
      Fig 4: Removing Bolts Which Secure The Power Steering Pipe Brackets
      G00928740Courtesy of SUBARU OF AMERICA, INC.
    4. Remove the bolts which secure the power steering pump bracket.
      Fig 5: Removing Bolts Which Secure Power Steering Pump Bracket
      G00928741Courtesy of SUBARU OF AMERICA, INC.
    5. Remove the power steering tank from the bracket by pulling it upward.
      Fig 6: Removing Power Steering Tank From Bracket By Pulling It Upward
      G00928742Courtesy of SUBARU OF AMERICA, INC.
    6. Place the power steering pump on the right side wheel apron.
      Fig 7: Placing Power Steering Pump
      G00928743Courtesy of SUBARU OF AMERICA, INC.
  12. Disconnect the emission hose (A) and connector (B) from the PCV hose assembly.
    Fig 8: Identifying Connector & PCV Hose Assembly
    G00928744Courtesy of SUBARU OF AMERICA, INC.
  13. Disconnect the engine coolant hoses from the throttle body.
    Fig 9: Disconnecting Engine Coolant Hoses From Throttle Body
    G00928745Courtesy of SUBARU OF AMERICA, INC.
  14. Disconnect the brake booster hose.
    Fig 10: Disconnecting Rake Booster Hose
    G00928746Courtesy of SUBARU OF AMERICA, INC.
  15. Disconnect the pressure hose from the intake duct.
    Fig 11: Disconnecting Pressure Hose From Intake Duct
    G00928747Courtesy of SUBARU OF AMERICA, INC.
  16. Disconnect the engine harness connectors from the bulkhead harness connectors.
    Fig 12: Disconnecting Engine Harness Connectors From Bulkhead Harness Connectors (1 Of 2)
    G00928748Courtesy of SUBARU OF AMERICA, INC.
    Fig 13: Disconnecting Engine Harness Connectors From Bulkhead Harness Connectors (2 Of 2)
    G00928749Courtesy of SUBARU OF AMERICA, INC.
  17. Disconnect the connectors from the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).
    Fig 14: Disconnecting Connectors From Oil Pressure Switch Crankshaft Position Sensor
    G00928750Courtesy of SUBARU OF AMERICA, INC.
  18. Disconnect the knock sensor connector.
    Fig 15: Disconnecting Knock Sensor Connector
    G00928751Courtesy of SUBARU OF AMERICA, INC.
  19. Disconnect the connector from the camshaft position sensor.
    Fig 16: Disconnecting Connector From Camshaft Position Sensor
    G00928752Courtesy of SUBARU OF AMERICA, INC.
  20. Disconnect the connector from the ignition coil.
    Fig 17: Disconnecting Connector From Ignition Coil
    G00928753Courtesy of SUBARU OF AMERICA, INC.
  21. Disconnect the engine harness fixed by clip (A) from the bracket.
    Fig 18: Disconnecting Engine Harness Fixed By Clip From Bracket
    G00928754Courtesy of SUBARU OF AMERICA, INC.
  22. Disconnect the fuel delivery hose, return hose and evaporation hose.
    CAUTION:
    • Do not spill fuel. 
    • Catch fuel from hoses in a container or cloth. 
    Fig 19: Catching Fuel From Hoses
    G00928755Courtesy of SUBARU OF AMERICA, INC.
  23. Remove the bolts which secure the intake manifold to the cylinder heads.
    Fig 20: Removing Bolts Which Secure Intake Manifold To Cylinder Heads
    G00928756Courtesy of SUBARU OF AMERICA, INC.
  24. Remove the intake manifold.