2008 Subaru Forester XT, AutomaticFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Installation

  1. Install the intake manifold onto cylinder heads.
    NOTE: Use a new gasket.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.1 ft-lb) 

    Fig 1: Identifying Intake Manifold Onto Cylinder Heads
    G04998276Courtesy of SUBARU OF AMERICA, INC.
  2. Connect the fuel delivery hose, return hose, and evaporation hose.
    Fig 2: Identifying Fuel Delivery Hose, Return Hose And Evaporation Hose
    G04998278Courtesy of SUBARU OF AMERICA, INC.
  3. Connect the connector to the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).
    Fig 3: Identifying Engine Coolant Temperature Sensor, Oil Pressure Switch And Crankshaft Position Sensor
    G04998268Courtesy of SUBARU OF AMERICA, INC.
  4. Connect the connector to the knock sensor.
    Fig 4: Identifying Connector To Knock Sensor
    G04998269Courtesy of SUBARU OF AMERICA, INC.
  5. Connect the connectors to camshaft position sensor.
    Fig 5: Identifying Camshaft Position Sensor Bolt
    G04998270Courtesy of SUBARU OF AMERICA, INC.
  6. Connect the connector to the ignition coil.
    • RH side
      Fig 6: Identifying Connector To Ignition Coil (RH Side)
      G04998271Courtesy of SUBARU OF AMERICA, INC.
    • LH side
      Fig 7: Identifying Connector To Ignition Coil (LH Side)
      G04998272Courtesy of SUBARU OF AMERICA, INC.
  7. Connect the engine harness with clip (A) to the bracket.
    • RH side
      Fig 8: Identifying Engine Harness Clip (RH Side)
      G04998273Courtesy of SUBARU OF AMERICA, INC.
    • LH side
      Fig 9: Identifying Engine Harness Clip (LH Side)
      G04998274Courtesy of SUBARU OF AMERICA, INC.
  8. Connect the engine harness connectors to bulkhead harness connectors.
    Fig 10: Identifying Engine Harness Connectors From Bulk Head Harness Connector
    G05333465Courtesy of SUBARU OF AMERICA, INC.
  9. Connect the brake booster vacuum hose.
    Fig 11: Identifying Brake Booster Hose
    G04993261Courtesy of SUBARU OF AMERICA, INC.
  10. Connect the engine coolant hoses to throttle body.
    Fig 12: Identifying Engine Coolant Hoses From Throttle Body
    G04998254Courtesy of SUBARU OF AMERICA, INC.
  11. Connect the emission hose (A) and the connector (B) to the PCV hose assembly.
    Fig 13: Identifying Emission Hose And Connector
    G04998262Courtesy of SUBARU OF AMERICA, INC.
  12. Connect the pressure hose to the intake duct.
    Fig 14: Identifying Pressure Hose From Intake Duct
    G04998265Courtesy of SUBARU OF AMERICA, INC.
  13. Install the power steering pump.
    1. Install the reservoir tank to the bracket.
      Fig 15: Identifying Reservoir Tank From Bracket
      G04997330Courtesy of SUBARU OF AMERICA, INC.
    2. Connect the connector to the power steering pump switch.
      Fig 16: Identifying Power Steering Switch Connector
      G04998257Courtesy of SUBARU OF AMERICA, INC.
    3. Install the power steering pump, and tighten the bolts.

      Tightening torque: 

      22 N.m (2.2 kgf-m, 15.9 ft-lb) 

      Fig 17: Identifying Power Steering Pump Bracket
      G04998259Courtesy of SUBARU OF AMERICA, INC.
    4. Install the power steering pipe bracket onto the right side intake manifold.
      Fig 18: Identifying Power Steering Pipe Bracket With Bolts
      G04998258Courtesy of SUBARU OF AMERICA, INC.
    5. Install the front side V-belts. <Ref. to INSTALLATION , V-belt. >
  14. Install the coolant filler tank.

    <Ref. INSTALLATION , Coolant Filler Tank. >

  15. Install the intercooler. <Ref. to INSTALLATION , Intercooler. >
  16. Install the air cleaner element.
  17. Install the air cleaner upper cover and air intake duct as a unit. <Ref. to INSTALLATION , Air Cleaner Case. >
  18. Connect the connector to fuel pump relay.
    Fig 19: Identifying Fuel Pump Relay
    G04992306Courtesy of SUBARU OF AMERICA, INC.
  19. Install the passenger's side front side sill cover.
  20. Install the glove box. <Ref. INSTALLATION , Glove Box. >
  21. Install the collector cover.
  22. Connect the ground cable to the battery.
  23. Lift-up the vehicle.
  24. Install the under cover.
  25. Fill engine coolant.

    <Ref. FILLING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant. >

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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