2006 Subaru Baja Base, StandardFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Installation

  1. Install intake manifold onto cylinder heads.
    NOTE: Always use new gaskets.

    Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)Β 

    Fig 1: Locating Intake Manifold Bolts
    G04987847Courtesy of SUBARU OF AMERICA, INC.
  2. Connect fuel hoses.
    Fig 2: Connecting Fuel Hoses
    G04987849Courtesy of SUBARU OF AMERICA, INC.
  3. Install EGR pipe to intake manifold and cylinder head.

    Tightening torque: 33 N.m (3.4 kgf-m, 24.6 ft-lb)Β 

    Fig 3: Identifying EGR Pipe
    G04987845Courtesy of SUBARU OF AMERICA, INC.
  4. Connect connector to camshaft position sensor.
    Fig 4: Connecting Connector To Camshaft Position Sensor
    G04987844Courtesy of SUBARU OF AMERICA, INC.
  5. Connect connector to oil pressure switch.
    Fig 5: Connecting Connector To Oil Pressure Switch
    G04987843Courtesy of SUBARU OF AMERICA, INC.
  6. Connect connector to crankshaft position sensor.
    Fig 6: Connecting Connector To Crankshaft Position Sensor
    G04987842Courtesy of SUBARU OF AMERICA, INC.
  7. Connect knock sensor connector.
    Fig 7: Connecting Knock Sensor Connector
    G04999384Courtesy of SUBARU OF AMERICA, INC.
  8. Install knock sensor harness connector to connector bracket.
  9. Connect connectors to engine coolant temperature sensor.
    Fig 8: Connecting Connectors To Engine Coolant Temperature Sensor
    G04987840Courtesy of SUBARU OF AMERICA, INC.
  10. Install air cleaner case stay RH and engine harness bracket, and connect engine harness connectors to bulkhead connectors.
    Fig 9: Identifying Air Cleaner Case Stay RH
    G04987839Courtesy of SUBARU OF AMERICA, INC.
  11. Connect brake booster hose.
    Fig 10: Connecting Brake Booster Hose
    G04987838Courtesy of SUBARU OF AMERICA, INC.
  12. Connect engine coolant hose (A) to throttle body.
    Fig 11: Connecting Engine Coolant Hose To Throttle Body
    G04987837Courtesy of SUBARU OF AMERICA, INC.
  13. Connect PCV hose to intake manifold.
    Fig 12: Connecting PCV Hose To Intake Manifold
    G04987836Courtesy of SUBARU OF AMERICA, INC.
  14. Connect spark plug cords to spark plugs.
  15. Install power steering pump and tank on brackets.
    1. Install power steering tank on bracket.
      Fig 13: Placing Power Steering Tank On Bracket
      G04988248Courtesy of SUBARU OF AMERICA, INC.
    2. Connect connector to power steering pump switch.
      Fig 14: Connecting Connector To Power Steering Pump Switch
      G04987833Courtesy of SUBARU OF AMERICA, INC.
    3. Tighten bolts which install power steering pump on bracket.

      Tightening torque: 22 N.m (2.2 kgf-m, 15.9 ft-lb)Β 

      Fig 15: Locating Power Steering Pump Bracket Bolts
      G04997328Courtesy of SUBARU OF AMERICA, INC.
    4. Install power steering pipes onto right side intake manifold protector.
      Fig 16: Identifying Power Steering Pipes Bolts
      G04987831Courtesy of SUBARU OF AMERICA, INC.
    5. Install front V-belt.

      < Ref. to INSTALLATION , V-BELT. >

    6. Install resonator chamber.

      Tightening torque: 33 N.m (3.4 kgf-m, 24.6 ft-lb)Β 

      Fig 17: Identifying Resonator Chamber
      G04987864Courtesy of SUBARU OF AMERICA, INC.
  16. Connect accelerator control cable (A).

    < Ref. to INSTALLATION , ACCELERATOR CONTROL CABLE. >

  17. Connect cruise control cable (B). (With cruise control models)
    Fig 18: Connecting Cruise Control Cable
    G04987826Courtesy of SUBARU OF AMERICA, INC.
  18. Install air intake duct and air cleaner case.

    < Ref. to INSTALLATION , AIR INTAKE DUCT > and < Ref. to INSTALLATION , AIR CLEANER. >

  19. Connect connector to fuel pump relay.
    Fig 19: Connecting Connector To Fuel Pump Relay
    G04989146Courtesy of SUBARU OF AMERICA, INC.
  20. Connect battery ground cable.
    Fig 20: Connecting Battery Ground Cable
    G04988132Courtesy 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.