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Home › Subaru › 2009 › Impreza WRX, 4D Sedan › Repair and Diagnosis › Engine Performance › Engine Control Systems › Fuel Injection System (H4DOTC) › Intake Manifold › Removal

Intake Manifold: Removal

  1. Set the vehicle on a lift.
  2. Remove the V-belt covers.
    Fig 1: Locating V-Belt Covers
    G05660761Courtesy of SUBARU OF AMERICA, INC.
  3. Collect the refrigerant from A/C system. Refer to PROCEDURE , Refrigerant Recovery Procedure.
  4. Release the fuel pressure. Refer to RELEASING OF FUEL PRESSURE , PROCEDURE, Fuel.
  5. Disconnect the ground cable from battery.
    Fig 2: Identifying Battery Ground Cable
    G05019586Courtesy of SUBARU OF AMERICA, INC.
  6. Open the fuel filler lid and remove the fuel filler cap.
  7. Lift up the vehicle.
  8. Remove the under cover.
  9. Drain approximately 3.0 C (3.2 US qt, 2.6 lmp qt) of coolant. Refer to DRAINING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant.
  10. Remove the air intake duct. Refer to REMOVAL , Air Intake Duct.
  11. Remove the air intake boot.
    Fig 3: Locating Air Intake Boot And Air Intake Duct
    G05955017Courtesy of SUBARU OF AMERICA, INC.
  12. Remove the intercooler. Refer to REMOVAL , Intercooler.
  13. Remove the generator. Refer to REMOVAL , Generator.
  14. Remove the coolant filler tank. Refer to REMOVAL , Coolant Filler Tank.
  15. Disconnect the A/C pressure hoses from A/C compressor. Refer to REMOVAL , Hose and Pipe.
  16. Disconnect the vacuum hose (A) and the connector (B) from the PCV hose assembly.
    Fig 4: Identifying Vacuum Hose And Connector
    G05954723Courtesy of SUBARU OF AMERICA, INC.
  17. Remove the connector from the PCV hose assembly.
    Fig 5: Identifying PCV Hose Assembly Connector
    G05954724Courtesy of SUBARU OF AMERICA, INC.
  18. Remove the bolts which secure the air by-pass pipe and PCV pipe to the intake manifold, and loosen the clamp which connects the throttle body and duct.
    Fig 6: Locating Air By-Pass Pipe And PCV Pipe With Bolts
    G05340064Courtesy of SUBARU OF AMERICA, INC.
  19. Remove the duct from the throttle body.
  20. Disconnect the engine coolant hose from throttle body.
    Fig 7: Identifying Engine Coolant Hoses
    G05954721Courtesy of SUBARU OF AMERICA, INC.
  21. Disconnect the brake booster vacuum hose.
    Fig 8: Identifying Brake Booster Vacuum Hose
    G05954727Courtesy of SUBARU OF AMERICA, INC.
  22. Disconnect the PCV hose from the rocker cover.
    NOTE: For the PCV hose affixed with the clamp, fit the depression in the ST with the protrusion of the clamp as shown in the figure below, unlock the clamp and disconnect.

    ST 18353AA000 CLAMP PLIERS

    Fig 9: Identifying ST Fitting Position Of Protrusion With Clamp
    G05340073Courtesy of SUBARU OF AMERICA, INC.
  23. Disconnect the air control hose (A) from the wastegate actuator, and loosen the clamp that holds the turbocharger on the intake duct.
    • Except for WRX-SS model
      Fig 10: Identifying Air Control Hose (Except For WRX-SS Model)
      G05954729Courtesy of SUBARU OF AMERICA, INC.
    • WRX-SS model
    Fig 11: Identifying Air Control Hose (WRX-SS Model)
    G06351214Courtesy of SUBARU OF AMERICA, INC.
  24. Disconnect the bulkhead harness connectors from the engine harness connectors.
    Fig 12: Identifying Bulkhead Harness Connector And Engine Harness Connector
    G05954730Courtesy of SUBARU OF AMERICA, INC.
  25. Remove the engine harness connector from the engine harness bracket.
    Fig 13: Locating Engine Harness Connector From Engine Harness Bracket
    G06344557Courtesy of SUBARU OF AMERICA, INC.
  26. Disconnect the connectors from the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).
    Fig 14: Identifying Engine Coolant Temperature Sensor, Oil Pressure Switch And Crankshaft Position Sensor Connectors
    G04998268Courtesy of SUBARU OF AMERICA, INC.
  27. Disconnect the connector from power steering pump switch.
    Fig 15: Identifying Power Steering Pump Switch Connector
    G05340076Courtesy of SUBARU OF AMERICA, INC.
  28. Disconnect the knock sensor connector.
    Fig 16: Disconnecting Knock Sensor Connector
    G05954733Courtesy of SUBARU OF AMERICA, INC.
  29. Disconnect the connector from the secondary air combination valve.
    Fig 17: Identifying Secondary Air Combination Valve To Connector
    G05954734Courtesy of SUBARU OF AMERICA, INC.
  30. Disconnect the connector from camshaft position sensor.
    Fig 18: Identifying Camshaft Position Sensor To Connectors
    G05954735Courtesy of SUBARU OF AMERICA, INC.
  31. Disconnect the connector from the oil flow control solenoid valve.
    Fig 19: Identifying Oil Flow Control Solenoid Valve To Connector
    G05954736Courtesy of SUBARU OF AMERICA, INC.
  32. Disconnect the air duct from the secondary air pump, and remove the bolts securing the air duct on the rocker cover LH.
    Fig 20: Locating Air Duct On Rocker Cover LH And Bolts
    G05954737Courtesy of SUBARU OF AMERICA, INC.
  33. Disconnect the connector from ignition coil.
    Fig 21: Locating Ignition Coil Connector
    G06335009Courtesy of SUBARU OF AMERICA, INC.
  34. Disconnect the connector from the front oxygen. (A/F) sensor, and remove the clip (A) and stay (B) which hold the engine harness to the rocker cover RH.
    Fig 22: Locating Front Oxygen (A/F) Sensor Connector
    G06351225Courtesy of SUBARU OF AMERICA, INC.
  35. Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose.

    ST 42099AE000 QUICK CONNECTOR RELEASE

    CAUTION:
    • Be careful not to spill fuel.
    • Catch the fuel from hoses using a container or cloth.
    Fig 23: Attaching ST To Fuel Delivery Pipe
    G06351226Courtesy of SUBARU OF AMERICA, INC.
  36. Disconnect the fuel return hose using the ST.

    ST 18371AA000 CONNECTOR REMOVER

    CAUTION:
    • Be careful not to spill fuel.
    • Catch the fuel from hoses using a container or cloth.
    1. Attach ST to the fuel return pipe as shown in the figure.
      Fig 24: Attaching ST To Fuel Return Pipe
      G05340084Courtesy of SUBARU OF AMERICA, INC.
    2. Insert the front side of ST into the quick connector.
      Fig 25: Inserting Front Side Of ST Into Quick Connector
      G05340085Courtesy of SUBARU OF AMERICA, INC.
    3. Insert the back side of ST into the quick connector and push ST in the direction of arrow mark to disconnect the fuel return hose.
    Fig 26: Pushing ST In Direction
    G05340086Courtesy of SUBARU OF AMERICA, INC.
  37. Remove the clip and disconnect the evaporation hose from the fuel pipe.
    Fig 27: Identifying Evaporation Hose And Fuel Pipe
    G05340087Courtesy of SUBARU OF AMERICA, INC.
  38. Remove the intake manifold from cylinder head.
Fig 28: Identifying Tumble Generator Valve Assembly And Cylinder Head
G05340088Courtesy of SUBARU OF AMERICA, INC.
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