2002 Subaru Forester BaseFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Disassembly

  1. Disconnect engine ground terminal from intake manifold.
    Fig 1: Disconnecting Engine Ground Terminal From Intake Manifold
    G02861790Courtesy of SUBARU OF AMERICA, INC.
  2. Disconnect connector from ignition coil and ignitor assembly.
    Fig 2: Disconnecting Connector From Ignition Coil And Ignitor Assembly
    G02861791Courtesy of SUBARU OF AMERICA, INC.
  3. Remove ignition coil and ignitor assembly.
    Fig 3: Removing Ignition Coil And Ignitor Assembly
    G02861792Courtesy of SUBARU OF AMERICA, INC.
  4. Disconnect connector from intake air temperature and pressure sensor.
    Fig 4: Disconnecting Connector From Intake Air Temperature And Pressure Sensor
    G02861793Courtesy of SUBARU OF AMERICA, INC.
  5. Remove intake air temperature and pressure sensor from intake manifold.
    Fig 5: Removing Intake Air Temperature And Pressure Sensor
    G02861794Courtesy of SUBARU OF AMERICA, INC.
  6. Disconnect connectors from throttle position sensor and idle air control solenoid valve.
    Fig 6: Disconnecting Connectors From Throttle Position Sensor And Idle Air Control Solenoid Valve
    G02861795Courtesy of SUBARU OF AMERICA, INC.
  7. Disconnect air by-pass hose from throttle body.
    Fig 7: Disconnecting Air By-Pass Hose From Throttle Body
    G02861796Courtesy of SUBARU OF AMERICA, INC.
  8. Remove throttle body.
    Fig 8: Removing Throttle Body
    G02861797Courtesy of SUBARU OF AMERICA, INC.
  9. Disconnect connector from air assist injector solenoid valve.
  10. Disconnect air by-pass hoses from air assist solenoid valve.
    Fig 9: Disconnecting Air By-Pass Hoses From Air Assist Solenoid Valve
    G02861798Courtesy of SUBARU OF AMERICA, INC.
  11. Remove air assist injector solenoid valve from intake manifold.
    Fig 10: Removing Air Assist Injector Solenoid Valve From Intake Manifold
    G02861799Courtesy of SUBARU OF AMERICA, INC.
  12. Disconnect pressure regulator vacuum hose from intake manifold.
    Fig 11: Disconnecting Pressure Regulator Vacuum Hose From Intake Manifold
    G02861800Courtesy of SUBARU OF AMERICA, INC.
  13. Disconnect connectors from fuel injectors.
    Fig 12: Disconnecting Connectors From Fuel Injectors
    G02861801Courtesy of SUBARU OF AMERICA, INC.
  14. Disconnect connector from purge control solenoid valve.
    Fig 13: Disconnecting Connector From Purge Control Solenoid Valve
    G02861802Courtesy of SUBARU OF AMERICA, INC.
  15. Disconnect air by-pass hose from purge control solenoid valve.
  16. Remove harness bands (*) which hold engine harness onto intake manifold.
    Fig 14: Removing Harness Bands
    G02861803Courtesy of SUBARU OF AMERICA, INC.
  17. Remove engine harness from intake manifold.
  18. Remove purge control solenoid valve.
    Fig 15: Removing Purge Control Solenoid Valve
    G02861804Courtesy of SUBARU OF AMERICA, INC.
  19. Remove bolt which installs injector pipe on intake manifold as shown in figure.
    Fig 16: Removing Injector Pipe Bolt
    G02861805Courtesy of SUBARU OF AMERICA, INC.
  20. Remove bolt which installs injector pipe on intake manifold.
    Fig 17: Removing Injector Pipe On Intake Manifold Bolt
    G02861806Courtesy of SUBARU OF AMERICA, INC.
  21. Remove two bolts which hold fuel pipes on the left side of intake manifold.
    Fig 18: Removing Two Fuel Pipe Bolts
    G02861807Courtesy of SUBARU OF AMERICA, INC.
  22. Remove fuel injectors.
    1. Remove fuel injector securing clip.
      Fig 19: Removing Fuel Injector Securing Clip
      G02861808Courtesy of SUBARU OF AMERICA, INC.
    2. Remove fuel injector while lifting up fuel injector pipe.
    Fig 20: Removing Fuel Injector
    G02861809Courtesy of SUBARU OF AMERICA, INC.
  23. Disconnect air by-pass hoses from intake manifold.
    Fig 21: Disconnecting Air By-Pass Hoses From Intake Manifold
    G02861810Courtesy of SUBARU OF AMERICA, INC.
  24. Loosen clamp which holds front left side fuel hose to injector pipe and remove the pipe from fuel hose.
    Fig 22: Loosening Front Left Side Fuel Hose Clamp
    G02861811Courtesy of SUBARU OF AMERICA, INC.
  25. Loosen clamp which holds front right side fuel hose to injector pipe and remove the pipe from fuel hose.
    Fig 23: Loosening Front Right Side Fuel Hose Clamp
    G02861812Courtesy of SUBARU OF AMERICA, INC.
  26. Remove fuel injector pipe.
    Fig 24: Removing Fuel Injector Pipe
    G02861813Courtesy of SUBARU OF AMERICA, INC.
  27. Remove bolt which installs fuel pipes on intake manifold.
    Fig 25: Removing Fuel Pipes Bolts
    G02861814Courtesy of SUBARU OF AMERICA, INC.
  28. Remove fuel pipe assembly and pressure regulator, from intake manifold.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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