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Home >> Subaru >> 2005 >> Baja Turbo, Standard >> 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) 

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

    Tightening torque: 

    19 N.m (1.94 kgf-m, 13.7 ft-lb) 

    Fig 1: Installing Air Intake Duct To The Intake Manifold
    G03749043Courtesy 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 2: Installing Fuel Pipe Assembly And Pressure Regulator To The Intake Manifold
    G03749044Courtesy 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 3: Connecting Left Side Fuel Hose To Injector Pipe, And Tighten The Clamp Screw
    G03749045Courtesy 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 4: Connecting Right Side Fuel Hose To Injector Pipe, And Tighten The Clamp Screw
    G03749046Courtesy 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 5: Installing Harness Bracket Which Holds The Engine Harness Onto Intake Manifold
    G03749047Courtesy 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 6: Installing Bolt Which Hold The Fuel Injector Pipe Onto Intake Manifold (LH Side) (1 Of 2)
      G03749048Courtesy of SUBARU OF AMERICA, INC.
      Fig 7: Installing Bolt Which Hold The Fuel Injector Pipe Onto Intake Manifold (LH Side) (2 Of 2)
      G03749049Courtesy of SUBARU OF AMERICA, INC.
    • RH SIDE
      Fig 8: Installing Bolt Which Hold The Fuel Injector Pipe Onto Intake Manifold (RH Side) (1 Of 2)
      G03749050Courtesy of SUBARU OF AMERICA, INC.
      Fig 9: Installing Bolt Which Hold The Fuel Injector Pipe Onto Intake Manifold (RH Side) (2 Of 2)
      G03749051Courtesy of SUBARU OF AMERICA, INC.
  11. Tighten the two bolts which install the fuel pipes on the left side of intake manifold.

    Tightening torque: 

    6.4 N.m (0.65 kgf-m, 4.8 ft-lb) 

    Fig 10: Tightening The Two Bolts On Fuel Pipes On The Left Side Of Intake Manifold
    G03749052Courtesy of SUBARU OF AMERICA, INC.
  12. Connect the evaporation hoses to the purge valve.
    NOTE: Connect the evaporation hoses as shown in Fig 11 .
    Fig 11: Connecting Evaporation Hoses
    G03749053Courtesy of SUBARU OF AMERICA, INC.
  13. Connect the evaporation hose and purge valve to the intake manifold.
    Fig 12: Connecting The Evaporation Hose And Purge Valve To The Intake Manifold
    G03749054Courtesy 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 13: Installing The Purge Control Solenoid Valve
    G03749055Courtesy of SUBARU OF AMERICA, INC.
  15. Connect the hoses to the purge control solenoid valve.
    NOTE: Connect the evaporation hoses as shown in Fig 14 .
    Fig 14: Connecting Evaporation Hoses
    G03749056Courtesy 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 15: Connecting Connector To The Purge Control Solenoid Valve
    G03749057Courtesy of SUBARU OF AMERICA, INC.
  18. Connect the connector to the tumble generator valve actuator.
    Fig 16: Connecting Connector To The Tumble Generator Valve Actuator
    G03749058Courtesy of SUBARU OF AMERICA, INC.
  19. Connect the connector to the fuel injector.
    Fig 17: Connecting Connector To The Fuel Injector
    G03749059Courtesy 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 18: Installing Throttle Body To The Intake Manifold
    G03749060Courtesy of SUBARU OF AMERICA, INC.
  21. Connect the connector to the throttle position sensor (A) and manifold absolute pressure sensor (B).
    Fig 19: Connecting Connector To The Throttle Position Sensor And Manifold Absolute Pressure Sensor
    G03749061Courtesy 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 20: Installing Engine Ground Terminal To The Intake Manifold
    G03749062Courtesy of SUBARU OF AMERICA, INC.
    Fig 21: Identifying Engine Ground Terminal
    G03749063Courtesy of SUBARU OF AMERICA, INC.