2015 Subaru WRX STI Launch EditionFACTORY 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, 18.4 ft-lb) 

    Fig 1: Locating Cylinder Head Intake Manifold Bolts
    G08538655Courtesy of SUBARU OF AMERICA, INC.
  2. Connect the fuel delivery hose, fuel return hose, and evaporation hose.
    Fig 2: Identifying Fuel Delivery Hose, Return Hose And Evaporation Hose
    G10264727Courtesy of SUBARU OF AMERICA, INC.
  3. Fix the engine harness to the rocker cover LH with the air duct.

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 3: Locating Rocker Cover LH Engine Harness Bolts
    G08538653Courtesy of SUBARU OF AMERICA, INC.
  4. Fix the engine harness to the rocker cover RH with clips (A).
    Fig 4: Identifying Rocker Cover RH Engine Harness Clips
    G06344566Courtesy of SUBARU OF AMERICA, INC.
  5. Lift up the vehicle.
  6. Connect connector (A) to the exhaust camshaft position sensor, connector (B) to the exhaust oil flow control solenoid valve, connector (C) to the ignition coil.
    Fig 5: Identifying Exhaust Camshaft Position Sensor And Oil Flow Control Solenoid Valve Connectors
    G08538651Courtesy of SUBARU OF AMERICA, INC.
  7. Install the engine harness cover. (right side only.)

    Tightening torque: 

    5 N.m (0.5 kgf-m, 3.7 ft-lb) 

    Fig 6: Identifying Engine Harness Cover
    G06344564Courtesy of SUBARU OF AMERICA, INC.
  8. Install the clip securing the engine harness. (Left side only)
    Fig 7: Locating Engine Harness Clip
    G10264720Courtesy of SUBARU OF AMERICA, INC.
  9. Lower the vehicle.
  10. Connect the connector to the intake oil flow control solenoid valve.
    Fig 8: Locating Intake Oil Flow Control Solenoid Valve Connector
    G06344563Courtesy of SUBARU OF AMERICA, INC.
  11. Connect the connector to the intake camshaft position sensor.
    Fig 9: Locating Intake Camshaft Position Sensor Connector
    G06344562Courtesy of SUBARU OF AMERICA, INC.
  12. Connect the connector to the secondary air combination valve.
    Fig 10: Locating Secondary Air Combination Valve Connector
    G06344561Courtesy of SUBARU OF AMERICA, INC.
  13. Connect the connector to the knock sensor.
    Fig 11: Locating Knock Sensor Connector
    G06344560Courtesy of SUBARU OF AMERICA, INC.
  14. Connect the connector to the power steering pump switch.
    Fig 12: Locating Power Steering Pump Switch Connector
    G10264737Courtesy of SUBARU OF AMERICA, INC.
  15. Connect the connector (A) to the engine coolant temperature sensor, connector (B) to the oil pressure switch, and the connector (C) to the crankshaft position sensor.
    Fig 13: Identifying Engine Coolant Temperature Sensor And Crankshaft Position Sensor Connectors
    G08538644Courtesy of SUBARU OF AMERICA, INC.
  16. Install the engine harness connector to engine harness bracket, then connect the bulkhead harness connector to the engine harness connector.
    Fig 14: Locating Engine Harness Connector
    G10264739Courtesy of SUBARU OF AMERICA, INC.
  17. Install the engine harness to clip (A).
    Fig 15: Identifying Engine Harness Clip
    G08538641Courtesy of SUBARU OF AMERICA, INC.
  18. Install the engine coolant hose to the water tank pipe.
    Fig 16: Locating Water Tank Pipe Engine Coolant Hose
    G08538640Courtesy of SUBARU OF AMERICA, INC.
  19. Connect the air control hose (A) to the wastegate actuator, and install the turbocharger to the intake duct.

    Tightening torque: 

    3 N.m (0.3 kgf-m, 2.2 ft-lb) 

    Fig 17: Locating Turbocharger Intake Duct Clamp
    G06344555Courtesy of SUBARU OF AMERICA, INC.
  20. Connect the vacuum hose (A) and connector (B) to the PCV hose assembly B.
    Fig 18: Identifying PCV Hose Assembly B Connector
    G10264708Courtesy of SUBARU OF AMERICA, INC.
  21. Install the vacuum hose to clip (B), and install the PCV hose assembly A to clip (A).
    Fig 19: Identifying PCV Hose Assembly A And Vacuum Hose Clips
    G10264707Courtesy of SUBARU OF AMERICA, INC.
  22. Connect the connector to the PCV hose assembly A.
    Fig 20: Locating PCV Hose Assembly A Connector
    G10264706Courtesy of SUBARU OF AMERICA, INC.
  23. Connect the brake booster vacuum hose (A) and pressure regulator vacuum hose (B) to the intake manifold.
    Fig 21: Identifying Intake Manifold Brake Booster And Pressure Regulator Vacuum Hoses
    G08538635Courtesy of SUBARU OF AMERICA, INC.
  24. Connect the engine coolant hoses to throttle body.
    Fig 22: Locating Throttle Body Engine Coolant Hose
    G08538634Courtesy of SUBARU OF AMERICA, INC.
  25. Install the A/C pressure hoses to A/C compressor. <Ref. to INSTALLATION , Hose and Pipe.>
  26. Install the coolant filler tank. <Ref. to INSTALLATION , Coolant Filler Tank.>
  27. Install the generator. <Ref. to INSTALLATION , Generator.>
  28. Install the air by-pass valve. <Ref. to INSTALLATION , Air By-pass Valve.>
  29. Install the air intake boot.

    Tightening torque: 

    2.5 N.m (0.3 kgf-m, 1.8 ft-lb) 

    Fig 23: Locating Air Intake Boot
    G10264703Courtesy of SUBARU OF AMERICA, INC.
  30. Install the intercooler. <Ref. to INSTALLATION , Intercooler.>
  31. Install the chamber assembly. <Ref. to INSTALLATION , Chamber Assembly.>
  32. Install the air intake duct. <Ref. to INSTALLATION , Air Intake Duct.>
  33. Connect the battery ground terminal.
  34. Lift up the vehicle.
  35. Install the under cover. <Ref. to INSTALLATION , Front Under Cover.>
  36. Lower the vehicle.
  37. Install the V-belt cover.

    Tightening torque: 

    13 N.m (1.3 kgf-m, 9.6 ft-lb) 

    Fig 24: Locating V-Belt Cover
    G06344549Courtesy of SUBARU OF AMERICA, INC.
  38. Fill engine coolant. <Ref. to FILLING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant.>
  39. Charge the A/C system with refrigerant. <Ref. to PROCEDURE , Refrigerant Charging Procedure.>
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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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