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Home >> Subaru >> 2008 >> Impreza WRX STi >> 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. Release the fuel pressure.

    <Ref. to RELEASING OF FUEL PRESSURE , PROCEDURE, Fuel. >

  3. Disconnect the ground cable from battery.
    Fig 1: Identifying Battery Ground Cable
    G05019586Courtesy of SUBARU OF AMERICA, INC.
  4. Open the fuel filler flap lid, and remove the fuel filler cap.
  5. Lift up the vehicle.
  6. Remove the under cover.
  7. Drain approximately 3.0 l  (3.2 US qt, 2.6 lmp qt) of coolant.
  8. Remove the intake duct from the air cleaner case.
  9. Remove the intercooler. <Ref. to REMOVAL , Intercooler.>
  10. Remove the generator. <Ref. to REMOVAL , Generator. >
  11. Remove the coolant filler tank. <Ref. to REMOVAL , Coolant Filler Tank.>
  12. Disconnect the emission hose (A) and the connector (B) from the PCV hose assembly.
    Fig 2: Identifying Emission Hose And PCV Hose Assembly
    G05017736Courtesy of SUBARU OF AMERICA, INC.
    Fig 3: Identifying Connector And PCV Hose Assembly
    G05017737Courtesy of SUBARU OF AMERICA, INC.
  13. 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 4: Locating Throttle Body And Duct
    G05340064Courtesy of SUBARU OF AMERICA, INC.
  14. Remove the duct from the throttle body.
  15. Disconnect the engine coolant hoses from the throttle body.
    Fig 5: Identifying Engine Coolant Hoses To Throttle Body
    G05017733Courtesy of SUBARU OF AMERICA, INC.
  16. Disconnect the brake booster vacuum hose.
    Fig 6: Identifying Brake Booster Vacuum Hose
    G05017739Courtesy of SUBARU OF AMERICA, INC.
  17. Fit the cut out in the ST with the protrusion on the clamp to unlock, and disconnect the PCV hose from the rocker cover.

    ST 18353AA000 CLAMP PLIERS

    Fig 7: Identifying PCV Hose To Rocker Cover
    G05340073Courtesy of SUBARU OF AMERICA, INC.
  18. Disconnect the engine harness connectors from the bulk head harness connector.
    Fig 8: Identifying Engine Harness Connectors And Bulk Head Harness Connector
    G05660394Courtesy of SUBARU OF AMERICA, INC.
  19. Disconnect the connectors from the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).
    Fig 9: Identifying Engine Coolant Temperature Sensor, Oil Pressure Switch And Crankshaft Position Sensor
    G04998268Courtesy of SUBARU OF AMERICA, INC.
  20. Disconnect the connector from power steering pump switch.
    Fig 10: Identifying Power Steering Pump Switch
    G05340076Courtesy of SUBARU OF AMERICA, INC.
  21. Disconnect the knock sensor connector.
    Fig 11: Identifying Knock Sensor Connector
    G05660397Courtesy of SUBARU OF AMERICA, INC.
  22. Disconnect the connector from the secondary air combination valve.
    Fig 12: Identifying Secondary Air Combination Valve And Connector
    G05340078Courtesy of SUBARU OF AMERICA, INC.
  23. Disconnect the connector from the camshaft position sensor.
    Fig 13: Identifying Camshaft Position Sensor And Connector
    G05017744Courtesy of SUBARU OF AMERICA, INC.
  24. Disconnect the connector from the oil flow control solenoid valve.
    Fig 14: Identifying Oil Flow Control Solenoid Valve And Connector
    G05340080Courtesy of SUBARU OF AMERICA, INC.
  25. Disconnect the connector from ignition coil.
    Fig 15: Identifying Connector Of Ignition Coil
    G05017746Courtesy of SUBARU OF AMERICA, INC.
  26. Remove the engine harness fixed by clip (A) from the rocker cover.
    Fig 16: Identifying Engine Harness To Rocker Cover
    G05660402Courtesy of SUBARU OF AMERICA, INC.
  27. 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 17: Attaching ST To Fuel Delivery Pipe
    G05660403Courtesy of SUBARU OF AMERICA, INC.
  28. 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 18: Attaching ST To Fuel Return Pipe
      G05340084Courtesy of SUBARU OF AMERICA, INC.
    2. Insert the front side of ST into the quick connector.
      Fig 19: Identifying Front Side Of ST And 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 20: Locating Back Side Of ST And Quick Connector
      G05340086Courtesy of SUBARU OF AMERICA, INC.
  29. Remove the clip and disconnect the evaporation hose from the fuel pipe.
    Fig 21: Identifying Evaporation Hose And Fuel Pipe
    G05340087Courtesy of SUBARU OF AMERICA, INC.
  30. Remove the bolts which hold the tumble generator valve assembly onto the cylinder head.
    Fig 22: Identifying Tumble Generator Valve Assembly And Cylinder Head
    G05340088Courtesy of SUBARU OF AMERICA, INC.
  31. Remove the intake manifold.
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