2004 Subaru Forester XS, AutomaticFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Disassembly

  1. Disconnect the engine ground terminal from the intake manifold.
    Fig 1: Disconnecting Engine Ground Terminal From Intake Manifold
    G00994750Courtesy of SUBARU OF AMERICA, INC.
  2. Remove the ignition coil and ignitor assembly. Refer to REMOVAL , Ignition Coil and Ignitor Assembly.
  3. Remove the throttle body. Refer to REMOVAL , Throttle Body.
  4. Remove the EGR valve. Refer to REMOVAL , EGR Valve.
  5. Remove the air assist injector solenoid valve from the intake manifold. Refer to REMOVAL , Air Assist Injector Solenoid Valve.
  6. Disconnect the pressure regulator vacuum hose from the intake manifold.
    Fig 2: Disconnecting Pressure Regulator Vacuum Hose From Intake Manifold
    G00994751Courtesy of SUBARU OF AMERICA, INC.
  7. Remove the fuel pipe protector LH.
    Fig 3: Identifying Fuel Pipe Protector LH
    G00994752Courtesy of SUBARU OF AMERICA, INC.
  8. Remove the fuel pipe protector RH.
    Fig 4: Identifying Fuel Pipe Protector RH
    G00994753Courtesy of SUBARU OF AMERICA, INC.
  9. Disconnect the connectors from the fuel injectors.
    Fig 5: Disconnecting Connectors From Fuel Injectors
    G00994754Courtesy of SUBARU OF AMERICA, INC.
  10. Remove the purge control solenoid valve. Refer to REMOVAL , Ignition Coil and Ignitor Assembly.
  11. Remove the harness bands (A) and harness bracket which hold engine harness onto the intake manifold.
    Fig 6: Identifying Harness Bands & Harness Bracket
    G00994755Courtesy of SUBARU OF AMERICA, INC.
  12. Remove the engine harness from the intake manifold.
  13. Remove the bolt which installs injector pipe on the intake manifold as shown in figure.
    Fig 7: Identifying Bolt & Injector Pipe
    G00994756Courtesy of SUBARU OF AMERICA, INC.
  14. Remove the bolt which installs injector pipe on the intake manifold.
    Fig 8: Identifying Bolt & Injector Pipe
    G00994757Courtesy of SUBARU OF AMERICA, INC.
  15. Remove the bolts which hold fuel pipes on the left side intake manifold.
    Fig 9: Identifying Bolts & Fuel Pipes
    G00994758Courtesy of SUBARU OF AMERICA, INC.
  16. Remove the fuel injectors.
    1. Remove the fuel injector securing clip.
      Fig 10: Identifying Fuel Injector Securing Clip
      G00994759Courtesy of SUBARU OF AMERICA, INC.
    2. Remove the fuel injector while lifting up the fuel injector pipe.
      Fig 11: Identifying Fuel Injector
      G00994760Courtesy of SUBARU OF AMERICA, INC.
  17. Disconnect the air by-pass hoses from the intake manifold.
    Fig 12: Disconnecting Air By-Pass Hoses From Intake Manifold
    G00994761Courtesy of SUBARU OF AMERICA, INC.
  18. Loosen the clamp which holds the front left side fuel hose to the injector pipe and remove the pipe.
    Fig 13: Loosening Clamp Which Holds Front Left Side Fuel Hose To Injector Pipe
    G00994762Courtesy of SUBARU OF AMERICA, INC.
  19. Loosen the clamp which holds the front right side fuel hose to the injector pipe and remove the pipe.
    Fig 14: Loosening Clamp Which Holds Front Right Side Fuel Hose To Injector Pipe
    G00994763Courtesy of SUBARU OF AMERICA, INC.
  20. Remove the fuel injector pipe.
  21. Remove the bolt which installs the fuel pipes on the intake manifold.
    Fig 15: Identifying Bolt & Fuel Pipes
    G00994764Courtesy of SUBARU OF AMERICA, INC.
  22. Remove the fuel pipe assembly and pressure regulator, from the 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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