2004 Subaru Baja Turbo, AutomaticFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Assembly

NOTE: Replace the gasket with a new one.
  1. Install the tumble generator valve assembly to the intake manifold.

    Tightening torque:Β 

    8.25 N.m (0.84 kgf-m, 6.1 ft-lb)Β 

    Fig 1: Installing Tumble Generator Valve Assembly To Intake Manifold
    G00928795Courtesy of SUBARU OF AMERICA, INC.
  2. Install the air intake duct to the intake manifold.

    Tightening torque:Β 

    19 N.m (1.94 kgf-m, 13.7 ft-lb)Β 

    Fig 2: Installing Air Intake Duct To Intake Manifold
    G00928796Courtesy of SUBARU OF AMERICA, INC.
  3. Install the fuel pipe assembly and pressure regulator to the intake manifold.

    Tightening torque:Β 

    4.9 N.m (0.5 kgf-m, 3.6 ft-lb)Β 

    Fig 3: Installing Fuel Pipe Assembly
    G00928797Courtesy of SUBARU OF AMERICA, INC.
  4. Install the fuel injector pipe LH.
  5. Connect the left side fuel hose to injector pipe, and tighten the clamp screw.
    Fig 4: Installing Fuel Injector Pipe LH
    G00928798Courtesy of SUBARU OF AMERICA, INC.
  6. Install the fuel injector pipe RH.
  7. Connect the right side fuel hose to injector pipe, and tighten the clamp screw.
    Fig 5: Installing Fuel Injector Pipe RH
    G00928799Courtesy of SUBARU OF AMERICA, INC.
  8. Install the engine harness to the intake manifold.
  9. Install the harness bracket which holds the engine harness onto intake manifold.

    Tightening torque:Β 

    19 N.m (1.94 kgf-m, 13.7 ft-lb)Β 

    Fig 6: Installing Fuel Injector Pipe Onto Intake Manifold
    G00928800Courtesy of SUBARU OF AMERICA, INC.
  10. Tighten the bolts which install the fuel injector pipe onto intake manifold.

    Tightening torque:Β 

    19 N.m (1.94 kgf-m, 13.7 ft-lb)Β 

    • LH SIDE
      Fig 7: Tightening Bolts LH Side (1 Of 2)
      G00928801Courtesy of SUBARU OF AMERICA, INC.
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:

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

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