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Home › Subaru › 2005 › Forester XT, Automatic › Repair and Diagnosis › Engine Performance › Engine Control Systems › Fuel Injection - Fuel Systems (H4DOTC) › Intake Manifold › Removal

Intake Manifold: Removal

  1. Release the fuel pressure. < Ref. to RELEASING OF FUEL PRESSURE , Procedure, Fuel. >
  2. Open the fuel filler flap lid and remove the fuel filler cap.
  3. Disconnect the ground cable from battery.
    Fig 1: Disconnecting Ground Cable From Battery
    G03806252Courtesy of SUBARU OF AMERICA, INC.
  4. Lift up the vehicle.
  5. Remove the under cover.
  6. Drain the engine coolant about 3.0 l (3.2 US qt, 2.6 Imp qt).
    Fig 2: Removing Under Cover
    G03806253Courtesy of SUBARU OF AMERICA, INC.
  7. Remove the air cleaner upper cover and air intake boot. < Ref. to REMOVAL , Air Cleaner Case. >
  8. Remove the air cleaner element.
  9. Remove the intercooler. < Ref. to REMOVAL , Intercooler. >
  10. Remove the coolant filler tank. < Ref. to REMOVAL , Coolant Filler Tank. >
  11. Remove the power steering pump.
    1. Remove the front side V-belt. < Ref. to REMOVAL , V-Belt. >
    2. Disconnect the power steering switch connector.
      Fig 3: Disconnecting Power Steering Switch Connector
      G03806254Courtesy 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 Power Steering Pipe Brackets To Intake Manifold
      G03806255Courtesy of SUBARU OF AMERICA, INC.
    4. Remove the bolts which secure the power steering pump bracket.
      Fig 5: Removing Bolts Power Steering Pump Bracket
      G03806256Courtesy of SUBARU OF AMERICA, INC.
    5. Remove the reservoir tank from the bracket by pulling it upward.
      Fig 6: Removing Reservoir Tank From Bracket
      G03806257Courtesy of SUBARU OF AMERICA, INC.
    6. Place the power steering pump on the right side wheel apron.
      Fig 7: Placing Power Steering Pump On Right Side Wheel Apron
      G03806258Courtesy of SUBARU OF AMERICA, INC.
  12. Disconnect the emission hose (A) and connector (B) from the PCV hose assembly.
    Fig 8: Disconnecting Emission Hose
    G03806259Courtesy of SUBARU OF AMERICA, INC.
  13. Disconnect the engine coolant hoses from the throttle body.
    Fig 9: Disconnecting Engine Coolant Hoses From Throttle Body
    G03806260Courtesy of SUBARU OF AMERICA, INC.
  14. Disconnect the brake booster hose.
    Fig 10: Disconnecting Brake Booster Hose
    G03806261Courtesy of SUBARU OF AMERICA, INC.
  15. Disconnect the pressure hose from the intake duct.
    Fig 11: Disconnecting Pressure Hose From Intake Duct
    G03806262Courtesy 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
    G03806263Courtesy of SUBARU OF AMERICA, INC.
    Fig 13: Disconnecting Connectors
    G03806264Courtesy 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 Engine Coolant Temperature Sensor
    G03806265Courtesy of SUBARU OF AMERICA, INC.
  18. Disconnect the knock sensor connector.
    Fig 15: Disconnecting Knock Sensor Connector
    G03806266Courtesy of SUBARU OF AMERICA, INC.
  19. Disconnect the connector from the camshaft position sensor.
    Fig 16: Disconnecting Connector From Camshaft Position Sensor
    G03806267Courtesy of SUBARU OF AMERICA, INC.
  20. Disconnect the connector from the ignition coil.
    • RH SIDE
      Fig 17: Disconnecting Connector From Ignition Coil (RH)
      G03806268Courtesy of SUBARU OF AMERICA, INC.
    • LH SIDE
      Fig 18: Disconnecting Connector From Ignition Coil (LH)
      G03806269Courtesy of SUBARU OF AMERICA, INC.
  21. Disconnect the engine harness fixed by clip (A) from the bracket.
    • RH SIDE
      Fig 19: Disconnecting Engine Harness From Bracket (RH)
      G03806270Courtesy of SUBARU OF AMERICA, INC.
    • LH SIDE
      Fig 20: Disconnecting Engine Harness From Bracket (LH)
      G03806271Courtesy of SUBARU OF AMERICA, INC.
  22. Using ST, disconnect fuel hoses from fuel pipes. < Ref. to REMOVAL , Fuel Delivery, Return and Evaporation Lines. >
    CAUTION:
    • Be careful not to spill fuel.
    • Catch fuel from hoses using a container or cloth.

    ST 42099AE000 CONNECTOR REMOVER

    Fig 21: Disconnecting Fuel Hoses From Fuel Pipes Using Connector Remover ST 42099AE000
    G03806272Courtesy of SUBARU OF AMERICA, INC.
  23. Remove the bolts which secure the intake manifold to the cylinder heads.
    Fig 22: Removing Intake Manifold Bolts
    G03806273Courtesy of SUBARU OF AMERICA, INC.
  24. Remove the intake manifold.
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