Subaru Legacy (2005 year). Manual - part 38

FU(H4SO 2.0)-11

FUEL INJECTION (FUEL SYSTEM)

Intake Manifold

3. Intake Manifold

A: REMOVAL

1) Release the fuel pressure. <Ref. to FU(H4SO
2.0)-38, RELEASING OF FUEL PRESSURE,
PROCEDURE, Fuel.>
2) Open fuel filler flap lid, and remove fuel filler cap.
3) Disconnect the ground cable from battery.

4) Remove the air cleaner case and air intake
chamber. <Ref. to IN(H4SO 2.0)-5, REMOVAL, Air
Cleaner Case.> <Ref. to IN(H4SO 2.0)-7, REMOV-
AL, Air Intake Chamber.>
5) Disconnect the spark plug cords from spark
plugs.
6) Disconnect the engine coolant hoses from throt-
tle body.

7) Disconnect the PCV hoses from intake manifold.
8) Disconnect the brake booster hose.

9) Disconnect the engine harness connectors from
bulkhead harness connectors.

10) Disconnect the connectors from engine coolant
temperature sensor.

11) Disconnect the knock sensor connector.

12) Disconnect the connector from crankshaft posi-
tion sensor.

13) Disconnect the connector from power steering
pump switch (A).

IN-00203

FU-02060

FU-02089

FU-02061

FU-00055

FU-01334

FU-00056

FU(H4SO 2.0)-12

FUEL INJECTION (FUEL SYSTEM)

Intake Manifold

14) Disconnect the connector from oil pressure
switch (B).

15) Disconnect the connector from camshaft posi-
tion sensor.

16) Remove the EGR pipe from intake manifold.
(EC, EK, K4, ER model)

17) Disconnect the fuel hose from fuel pipe.

WARNING:
• Be careful not to spill fuel.

• Catch the fuel from hoses using a container
or cloth.

18) Remove the bolts which secure intake manifold
to cylinder head.

19) Remove the intake manifold.

B: INSTALLATION

1) Install the intake manifold onto cylinder heads.

NOTE:
Use a new gasket.

Tightening torque:

25 N

⋅

m (2.5 kgf-m, 18 ft-lb)

2) Connect the fuel hoses.

NOTE:
If fuel hoses or clamps are damaged, replace them
with new ones.

FU-01087

(B)

(A)

FU-01335

FU-00148

(A) Fuel delivery hose

(B) Return hose

(C) Evaporation hose

FU-02062

(A)

(C)

(B)

FU-00260

FU-00260

FU(H4SO 2.0)-13

FUEL INJECTION (FUEL SYSTEM)

Intake Manifold

Tightening torque:

1.25 N

⋅

m (0.13 kgf-m, 0.94 ft-lb)

3) Install the EGR pipe to intake manifold. (EC, EK,
K4, ER model)

Tightening torque:

34 N

⋅

m (3.4 kgf-m, 24.6 ft-lb)

4) Connect the connector to camshaft position sen-
sor.

5) Connect the connector to power steering pump
switch (A).

6) Connect the connector to oil pressure switch (B).

7) Connect the connector to crankshaft position
sensor.

8) Connect the knock sensor connector.

9) Connect the connectors to engine coolant tem-
perature sensor.

10) Connect the PCV hose to intake manifold.

(A) Fuel delivery hose

(B) Return hose

(C) Evaporation hose

FU-02062

(A)

(C)

(B)

FU-00148

FU-01335

FU-01087

(B)

(A)

FU-00056

FU-01334

FU-00055

FU(H4SO 2.0)-14

FUEL INJECTION (FUEL SYSTEM)

Intake Manifold

11) Connect the brake booster hose.

12) Connect the engine harness connectors to
bulkhead harness connectors.

13) Connect the engine coolant hoses to throttle
body.

14) Connect the spark plug cords to spark plugs.
15) Install the air cleaner case and air intake cham-
ber. <Ref. to IN(H4SO 2.0)-5, INSTALLATION, Air
Cleaner Case.> <Ref. to IN(H4SO 2.0)-7, INSTAL-
LATION, Air Intake Chamber.>
16) Install the fuse of fuel pump to main fuse box.
17) Connect the ground cable to battery.

C: DISASSEMBLY

1) Disconnect the engine ground terminal from in-
take manifold.

2) Remove the ignition coil and ignitor assembly.
<Ref. to IG(H4SO 2.0)-8, REMOVAL, Ignition Coil
and Ignitor Assembly.>
3) Remove the throttle body. <Ref. to FU(H4SO
2.0)-10, REMOVAL, Throttle Body.>
4) Remove the EGR valve. (EC, EK, K4, ER model)
<Ref. to FU(H4SO 2.0)-28, REMOVAL, EGR
Valve.>
5) Disconnect the pressure regulator vacuum hose
from intake manifold.

6) Remove the fuel pipe protector LH.

FU-02089

FU-02061

FU-02060

IN-00203

FU-02063

FU-02064

FU-02065