2004 Subaru Forester XT, 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.
    1. Tightening torque: 8.25 N.m (0.84 kgf-m, 6.1 ft-lb) 
    Fig 1: Identifying Tumble Generator Valve Assembly
    G00966302Courtesy of SUBARU OF AMERICA, INC.
  2. Install the air intake duct to the intake manifold.
    1. Tightening torque: 19 N.m (1.94 kgf-m, 13.7 ft-lb) 
    Fig 2: Identifying Air Intake Duct
    G00966303Courtesy of SUBARU OF AMERICA, INC.
  3. Install the fuel pipe assembly and pressure regulator to the intake manifold.
    1. Tightening torque: 4.9 N.m (0.5 kgf-m, 3.6 ft-lb) 
    Fig 3: Identifying Fuel Pipe Assembly & Pressure Regulator
    G00966304Courtesy 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: Identifying Left Side Fuel Hose
    G00966305Courtesy 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: Identifying Right Side Fuel Hose
    G00966306Courtesy 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.
    1. Tightening torque: 19 N.m (1.94 kgf-m, 13.7 ft-lb) 
    Fig 6: Identifying Harness Bracket
    G00966307Courtesy of SUBARU OF AMERICA, INC.
  10. Tighten the bolts which install the fuel injector pipe onto intake manifold.
    1. Tightening torque: 19 N.m(1.94 kgf-m, 13.7 ft-lb) 
    • LH SIDE
      Fig 7: Tightening Bolts LH Side (1 Of 2)
      G00966308Courtesy 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:

  • • 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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