Subaru Forester 1998-05

Intake Manifold

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Removal & Installation




CAUTION
The fuel injection system remains under pressure after the engine has been turned OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Mass Air Flow (MAF) sensor connector
     
    Air intake duct, air cleaner upper cover and the air cleaner element
     
    Accelerator cable and the cruise control cable, if equipped
     
    V-belt covers
     
    Power steering v-belt
     
    Power steering hose brackets from intake manifold
     
    Power steering pump and seat aside, do not disconnect hoses
     
    Spark plug wires from coil
     
    Positive Crankcase Ventilation (PCV) hose and vacuum hose from intake manifold
     
    Cruise control diaphragm vacuum hose, if equipped
     
    Engine coolant hoses from throttle body and Idle Air Control (IAC) solenoid valve
     
    Air bypass hose from IAC solenoid valve
     
    Brake booster hose
     
    Exhaust Gas Recirculation (EGR) pipe
     
    Engine harness bracket from transmission housing and disconnect connectors
     
    Coolant temperature sensor and thermometer connector
     
    Knock Sensor (KS) connector
     
    Camshaft Position (CMP) sensor connector
     
    Crankshaft Position (CKP) sensor connector
     
    Oil pressure switch connector
     
    Fuel hoses from fuel pipes
     
    Intake manifold
     
    Ground cable from the intake manifold
     
    Throttle Position (TP) sensor
     
    Ignition coil
     
    Fuel injectors
     
    Idle Air Control (IAC) solenoid valve
     
    Purge control solenoid valve
     
    Exhaust Gas Recirculation (EGR) solenoid valve
     
    Engine harness and band from intake manifold
     
    IAC solenoid valve from the intake manifold
     
    Throttle body from the intake manifold and discard the gasket
     
    Fuel pipes from intake manifold
     
    EGR and the purge control solenoid valves
     

  6.  

To install:

  1. Install or connect the following:

    EGR and the purge control solenoid valves
     
    Fuel pipes to the intake manifold
     
    Throttle body to the intake manifold and use a new gasket. Torque the bolts to 16 ft. lbs. (22 Nm).
     
    IAC solenoid valve to the intake manifold. Torque the bolts to 5 ft. lbs. (6.5 Nm).
     
    Engine harness and band to in take manifold
     
    EGR and the purge control solenoid valves
     
    TP sensor
     
    IAC solenoid valve
     
    Purge control solenoid valve
     
    Harness band
     
    Ground cable from the intake manifold
     
    Intake manifold. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Fuel hoses
     
    Oil pressure switch connector
     
    CKP sensor connector
     
    CMP sensor connector
     
    KS connector
     
    Coolant temperature sensor and thermometer connector
     
    Engine harness bracket to transmission housing and connect connectors
     
    EGR pipe. Torque to 25 ft. lbs. (34 Nm).
     
    Brake booster hose
     
    Engine coolant hoses to throttle body and IAC solenoid valve
     
    Brake booster hose
     
    Air bypass hose and coolant hose to IAC solenoid valve
     
    Engine coolant hoses to the throttle body and IAC solenoid valve
     
    Cruise control diaphragm vacuum hose, if equipped
     
    PCV hose and vacuum hose to intake manifold
     
    Spark plug wires to coil
     
    Power steering pump. Torque the bolts to 15 ft. lbs. (20 Nm).
     
    Power steering hose brackets to intake manifold
     
    Power steering V-belt
     
    V-belt covers
     
    Accelerator cable and the cruise control cable, if equipped
     
    Air intake duct, air cleaner upper cover and the air cleaner element
     
    Negative battery cable
     

  2.  



Click image to see an enlarged view

Fig. Intake manifold and related components-1999-2004 SOHC (Non-Turbo) engine



Click image to see an enlarged view

Fig. Intake manifold and related components-2004 DOHC (Turbo) engine

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a suitable container.
  4.  
  5. Remove or disconnect the following:

    Mass Air Flow (MAF) sensor connector, if necessary
     
    Air intake duct, air cleaner upper cover and the air cleaner element
     

  6.  
  7. Properly release the fuel pressure.

    Accelerator cable and the cruise control cable, if equipped
     
    Resonator chamber, if equipped
     
    V-belt cover(s)
     

  8.  
  9. Loosen the lock bolt and slider bolt, then remove the power steering belt
  10.  
  11. Remove or disconnect the following:
    NOTE
    The intake manifold sits on pins that protrude from the cylinder heads. Be sure the pins remain in the cylinder heads.



    Power steering pipe bracket-to-manifold bolts
     
    Bolts holding the power steering pump to the bracket
     
    Connector from the power steering pump switch, if equipped
     
    Power steering pump, and place on the right side wheel apron. Do NOT disconnect the fluid lines.
     
    Spark plug wires from the spark plugs
     
    Positive Crankcase Ventilation (PCV) hose and vacuum hose from the intake manifold
     
    Engine coolant hoses from the throttle body
     
    Brake booster hose
     
    Air cleaner case stay (right side) and engine harness bracket, if necessary
     
    Engine harness connectors form the bulkhead harness connectors
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Knock sensor, Camshaft Position (CMP) sensor and Crankshaft Position (CKP) sensor electrical connectors
     
    Oil pressure switch
     
    Fuel hoses from the fuel pipes
     
    Intake manifold mounting bolts
     
    Intake manifold and discard the gaskets
     

  12.  

To install:

  1. Install or connect the following:

    New gaskets
     
    Intake manifold to the engine. Tighten the mounting bolts to 16.7-19.5 ft. lbs. (23-27 Nm).
     
    Fuel hoses to the fuel pipes, be sure to secure the hoses with new clamps
     
    Knock sensor, CMP sensor, CKP sensor, oil pressure switch and ECT sensor wiring
     
    Engine harness bracket and engine harness connectors to bulkhead connectors
     
    EGR pipe, if removed
     
    Brake booster hose
     
    Engine coolant hose and air bypass hose to idle air control solenoid valve, if removed
     
    Engine coolant hoses to the throttle body
     
    PCV hoses to intake manifold
     
    Spark plug wires to ignition coil or plugs, as applicable
     
    Power steering pump to bracket. Tighten the bolts to 13-16.6 ft. lbs. (17.6-22.6 Nm).
     
    Power steering pipe brackets on right side of the intake manifold
     
    Bolt, which installs the power steering pump stiffener on the engine block, to 14.4-17.3 ft. lbs. (20-24 Nm)
     
    Power steering pump belt and adjust the belt as necessary
     
    V-belt cover(s)
     
    Resonator chamber, if equipped
     
    Accelerator cable and the cruise control cable, if equipped
     
    Air cleaner assembly
     
    MAF sensor connector, if disconnected
     

  2.  
  3. Connect the negative battery cable and refill the cooling system. Start the engine, and bleed the cooling system. Check for leaks.
  4.  



Click image to see an enlarged view

Fig. Intake manifold and related components-2005 SOHC (Non-Turbo) engine



Click image to see an enlarged view

Fig. Intake manifold and related components-2005 DOHC (Turbo) engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure. Remove the fuel cap.
  4.  
  5. Disconnect the negative battery cable. Drain the engine coolant.
  6.  
  7. If equipped, remove the under cover.
  8.  
  9. Remove the air intake duct, air cleaner case and air intake chamber.
  10.  
  11. If equipped, remove the intercooler.
  12.  
  13. Remove the alternator.
  14.  
  15. If equipped with DOHC engine, remove the coolant filler tank.
  16.  
  17. If equipped with SOHC engine, remove the spark plug wires.
  18.  
  19. Disconnect the engine coolant hoses from the throttle body. Disconnect the brake booster hose.
  20.  
  21. Disconnect the PCV hose from the intake manifold. Disconnect the engine harness electrical connectors from the bulkhead harness connectors.
  22.  
  23. Disconnect the engine coolant temperature sensor electrical connector, knock sensor electrical connector and crankshaft position sensor connector.
  24.  
  25. Disconnect the power steering pump switch electrical connector, oil pressure switch connector and camshaft sensor connector.
  26.  
  27. If equipped with DOHC engine, disconnect the oil flow solenoid valve electrical connector and the ignition coil connector.
  28.  
  29. If equipped with SOHC engine, remove the EGR pipe from the intake manifold and disconnect the fuel lines from the fuel pipe.
  30.  
  31. If equipped with DOHC engine, disconnect the fuel delivery hose, return hose and evaporation hose.
  32.  
  33. Remove the intake manifold retaining bolts. Remove the intake manifold from the engine.
  34.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use new intake manifold gaskets. Torque the manifold retaining bolts to specification and in alternating sequence.
  4.  
  5. Be sure to fill the cooling system with the proper grade and type engine coolant.
  6.  
  7. Start the engine and check for leaks, correct as required.
  8.  

DOHC Engines

CAUTION
The fuel injection system remains under pressure after the engine has been turned OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the engine undercover.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove the fuel filler cap.
  10.  
  11. Disconnect the negative battery cable.
  12.  
  13. Remove the air intake duct, air cleaner upper cover and the air cleaner element.
  14.  
  15. Remove the intercooler as follows:
    1. Disconnect the Positive Crankcase Ventilation (PCV) hose from the pipe.
    2.  
    3. Remove the PCV pipe from the intercooler.
    4.  
    5. Disconnect the air by-pass valve hose.
    6.  
    7. Remove the intercooler-to-bracket bolts.
    8.  
    9. Loosen the clamps that connect the intercooler to the turbocharger and throttle body.
    10.  
    11. Disconnect the intercooler duct from the turbocharger and remove the intercooler.
    12.  

  16.  
  17. Remove the coolant filler tank.
  18.  
  19. Loosen the power steering pump lock bolt and slider bolt. Remove the power steering belt.
  20.  
  21. Disconnect the power steering switch connector.
  22.  
  23. Remove the pipe with the bracket from the intake manifold and remove the power steering pump.
  24.  
  25. Remove the power steering tank from its bracket by pulling it up.
  26.  
  27. Place the power steering pump on the right wheel apron.
  28.  
  29. Disconnect the emission hose and the connector from the Positive Crankcase Ventilation (PCV) hose assembly.
  30.  
  31. Disconnect the coolant hoses from the throttle body.
  32.  
  33. Disconnect the brake booster hose.
  34.  
  35. Disconnect the pressure hose from the intake duct.
  36.  
  37. Disconnect the following electrical connectors:

    Engine harness connectors from the bulkhead connector
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Crankshaft Position (CMP) sensor connector
     
    Oil pressure switch connector
     
    Knock Sensor (KS) connector
     
    Camshaft Position (CKP) sensor connector
     
    Ignition coil connectors on both sides
     

  38.  
  39. Disconnect the clip attaching the engine harness to the bracket on both sides.
  40.  
  41. Disconnect the fuel delivery and return hoses and the evaporation hose.
  42.  
  43. Remove the bolts attaching the intake manifold to the heads.
  44.  
  45. Remove the intake manifold.
  46.  

To install:



Click image to see an enlarged view

Fig. Exploded view of the intake manifold-DOHC models

  1. Installation of the components is the reverse order of removal.
  2.  
  3. When installing the intake manifold, tighten the bolts to 18 ft. lbs. (25 Nm)
  4.  
  5. When installing the power steering pump, tighten the bolts to 16 ft. lbs. (22 Nm)
  6.  
  7. Refill the cooling system.
  8.  
  9. Start the engine, and bleed the cooling system.
  10.  
  11. Check for leaks.
  12.  

SOHC Engines

CAUTION
The fuel injection system remains under pressure after the engine has been turned OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Fuel filler cap
     
    Negative battery cable
     
    Air intake duct, air cleaner upper cover and the air cleaner element
     
    Accelerator cable and the cruise control cable, if equipped
     
    Resonator chamber
     
    V-belt covers
     
    Power steering V-belt
     
    Power steering hose brackets from intake manifold
     
    Power steering pump and set aside, do not disconnect hoses
     
    Spark plug wires
     
    Positive Crankcase Ventilation (PCV) hose and vacuum hose from intake manifold
     
    Engine coolant hoses from throttle body
     
    Brake booster hose
     
    Air cleaner case stay and engine harness bracket
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Knock Sensor (KS) connector
     
    Crankshaft Position (CMP) sensor connector
     
    Oil pressure switch connector
     
    Camshaft Position (CKP) sensor connector
     
    Exhaust Gas Recirculation (EGR) pipe from the intake manifold
     
    Fuel hoses from fuel pipes
     
    Intake manifold
     

  8.  


NOTE
The intake manifold sits on pins that protrude from the cylinder heads. Be sure the pins remain in the cylinder heads.

To install:



Click image to see an enlarged view

Fig. Exploded view of the intake manifold-2002-03 SOHC models shown



Click image to see an enlarged view

Fig. Exploded view of the intake manifold-2004 SOHC models shown

  1. Install or connect the following:

    Intake manifold and tighten the bolts to 18 ft. lbs. (25 Nm)
     
    Fuel hoses to the fuel pipes
     
    EGR pipe to the intake manifold and tighten the bolts to 24 ft. lbs. (34 Nm)
     
    CKP sensor connector
     
    Oil pressure switch connector
     
    CMP sensor connector
     
    KS connector
     
    ECT sensor connector
     
    Air cleaner case stay and engine harness bracket
     
    Brake booster hose
     
    Engine coolant hoses to throttle body
     
    PCV hose and vacuum hose to the intake manifold
     
    Spark plug wires
     
    Power steering pump and tighten the bracket bolts to 14 ft. lbs. (20 Nm)
     
    Power steering V-belt
     
    V-belt covers
     
    Resonator chamber
     
    Accelerator cable and the cruise control cable, if equipped
     
    Air intake duct, air cleaner upper cover and the air cleaner element
     
    Negative battery cable
     
    Fuel filler cap
     

  2.  
  3. Refill the cooling system.
  4.  
  5. Start the engine, and bleed the cooling system.
  6.  
  7. Check for leaks.
  8.  

 
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