2004 Subaru Baja Base, AutomaticFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Disassembly

  1. Disconnect engine ground terminal from intake manifold.
    Fig 1: Disconnecting Engine Ground Terminal From Intake Manifold
    G00898718Courtesy of SUBARU OF AMERICA, INC.
  2. Disconnect connector from ignition coil and ignitor assembly.
    Fig 2: Disconnecting Connector From Ignition Coil & Ignitor Assembly
    G00898719Courtesy of SUBARU OF AMERICA, INC.
  3. Remove ignition coil and ignitor assembly.
    Fig 3: Removing Ignition Coil & Ignitor Assembly
    G00898720Courtesy of SUBARU OF AMERICA, INC.
  4. Remove throttle body. Refer to REMOVAL , Throttle Body.
  5. Remove air assist injector solenoid valve. Refer to REMOVAL , Air Assist Injector Solenoid Valve.
  6. Remove EGR valve. Refer to REMOVAL , EGR Valve.
  7. Disconnect pressure regulator vacuum hose from intake manifold.
    Fig 4: Disconnecting Pressure Regulator Vacuum Hose From Intake Manifold
    G00898721Courtesy of SUBARU OF AMERICA, INC.
  8. Remove fuel pipe protector LH.
    Fig 5: Removing Fuel Pipe Protector LH
    G00898722Courtesy of SUBARU OF AMERICA, INC.
  9. Remove fuel pipe protector RH.
    Fig 6: Removing Fuel Pipe Protector RH
    G00898723Courtesy of SUBARU OF AMERICA, INC.
  10. Disconnect connectors from fuel injectors.
    Fig 7: Disconnecting Connectors From Fuel Injectors
    G00898724Courtesy of SUBARU OF AMERICA, INC.
  11. Disconnect connector from purge control solenoid valve.
    Fig 8: Disconnecting Connector From Purge Control Solenoid Valve
    G00898725Courtesy of SUBARU OF AMERICA, INC.
  12. Disconnect air by-pass hose from purge control solenoid valve.
  13. Remove harness bands (A) which hold engine harness onto intake manifold.
    Fig 9: Removing Harness Bands
    G00898726Courtesy of SUBARU OF AMERICA, INC.
  14. Remove engine harness from intake manifold.
  15. Remove purge control solenoid valve.
    Fig 10: Removing Purge Control Solenoid Valve
    G00898727Courtesy of SUBARU OF AMERICA, INC.
  16. Remove bolt which installs injector pipe on intake manifold as shown in figure.
    Fig 11: Removing Bolt Which Installs Injector Pipe On Intake Manifold
    G00898728Courtesy of SUBARU OF AMERICA, INC.
  17. Remove two bolts which hold fuel pipes on the left side of intake manifold.
    Fig 12: Removing Two Bolts Which Hold Fuel Pipes On Left Side Of Intake Manifold
    G00898729Courtesy of SUBARU OF AMERICA, INC.
  18. Remove fuel injectors.
    1. Remove fuel injector securing clip.
      Fig 13: Removing Fuel Injector Securing Clip
      G00898730Courtesy of SUBARU OF AMERICA, INC.
    2. Remove fuel injector while lifting up fuel injector pipe.
    Fig 14: Removing Fuel Injector
    G00898731Courtesy of SUBARU OF AMERICA, INC.
  19. Disconnect air by-pass hoses from intake manifold.
    Fig 15: Disconnecting Air By-Pass Hoses From Intake Manifold
    G00898732Courtesy of SUBARU OF AMERICA, INC.
  20. Loosen clamp which holds front left side fuel hose to injector pipe and remove the pipe from clamp.
    Fig 16: Removing Pipe From Clamp
    G00898733Courtesy of SUBARU OF AMERICA, INC.
  21. Loosen clamp which holds front right side fuel hose to injector pipe and remove the pipe from clamp.
    Fig 17: Removing Pipe From Clamp
    G00898734Courtesy of SUBARU OF AMERICA, INC.
  22. Remove fuel injector pipe.
  23. Remove bolt which installs fuel pipes on intake manifold.
    Fig 18: Removing Bolt Which Installs Fuel Pipes On Intake Manifold
    G00898735Courtesy of SUBARU OF AMERICA, INC.
  24. Remove fuel pipe assembly and pressure regulator, from intake manifold.
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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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