2005 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.

    Tightening torque: 

    8.25 N.m (0.84 kgf-m, 6.1 ft-lb) 

    Fig 1: Installing Tumble Generator Valve Assembly To Intake Manifold
    G03806314Courtesy of SUBARU OF AMERICA, INC.
  2. Install the air intake duct to the intake manifold.

    Tightening torque: 

    19 N.m (1.94 kgf-m, 13.7 ft-lb) 

    Fig 2: Installing Air Intake Duct To Intake Manifold
    G03806315Courtesy of SUBARU OF AMERICA, INC.
  3. Install the fuel pipe assembly and pressure regulator to the intake manifold.

    Tightening torque: 

    5 N.m (0.5 kgf-m, 3.7 ft-lb) 

    Fig 3: Installing Fuel Pipe Assembly And Pressure Regulator To Intake Manifold
    G03806316Courtesy 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: Connecting Left Side Fuel Hose To Injector Pipe
    G03806317Courtesy 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: Connecting Right Side Fuel Hose To Injector Pipe
    G03806318Courtesy 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: 

    19 N.m (1.94 kgf-m, 13.7 ft-lb) 

    Fig 6: Installing Harness Bracket
    G03806319Courtesy of SUBARU OF AMERICA, INC.
  10. Tightening the bolts which install the fuel injector pipe onto intake manifold.

    Tightening torque: 

    19 N.m (1.94 kgf-m, 13.7 ft-lb) 

    • LH SIDE
      Fig 7: Tightening Bolts
      G03806320Courtesy 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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