2018 Subaru Crosstrek Base, Automatic CVT TransFACTORY OEM SERVICE PROCEDURE

Intake Manifold Assembly: Removal

  1. If the fuel delivery tube is disconnected after removing the intake manifold assembly, perform the following work.
    1. Release the fuel pressure. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>Fuel>PROCEDURE>RELEASING OF FUEL PRESSURE .
    2. Open the fuel filler lid and remove the fuel filler cap.
      NOTE: This operation is required to release the inner pressure of the fuel tank.
  2. Remove the battery. Ref. to STARTING/CHARGING SYSTEMS (H4DO)>Battery>REMOVAL .
  3. Drain approximately 3.0 L (3.2 US qt, 2.6 Imp qt) of engine coolant. Ref. to COOLING (H4DO)>Engine Coolant>REPLACEMENT>DRAINING OF ENGINE COOLANT .
  4. Remove the clip from the air intake boot, and loosen the clamp.
    G11252776Courtesy of SUBARU OF AMERICA, INC.
  5. Remove the air intake boot, and place it aside so that it does not interfere with the work.
    CAUTION: Be careful not to pull out the PCV hose.
    G11252777Courtesy of SUBARU OF AMERICA, INC.
  6. Disconnect the preheater hose (A) from the throttle body, and disconnect the connector (B).
  7. Disconnect the connector (C) from manifold absolute pressure sensor.
  8. Disconnect the connector (D) from the purge control solenoid valve, and remove clip (E).
  9. Disconnect the evaporation hose (F) from the purge control solenoid valve.
  10. Disconnect the PCV hose (G).
  11. Remove the bolt (H) securing the fuel pipe.
    G11252783Courtesy of SUBARU OF AMERICA, INC.
  12. Disconnect the connector (A) from the tumble generator valve RH.
  13. Remove the fuel delivery tube clamp (B).
  14. Remove clip (C) securing the engine wiring harness.
    G11252784Courtesy of SUBARU OF AMERICA, INC.
  15. Remove nut (A) securing the EGR cooler to the EGR control valve.
  16. Remove stud bolt (B) using TORX® E8.
  17. Loosen bolts (C) securing the EGR cooler to the cylinder head RH.
    G11252785Courtesy of SUBARU OF AMERICA, INC.
  18. Remove the V-belt covers.
    G12391348Courtesy of SUBARU OF AMERICA, INC.
  19. Disconnect the connector (A), connector (B) and terminal (C). (Fixed capacity A/C model)
  20. Remove the clip (D) and clip (E) that secure the battery cable. (Fixed capacity A/C model)
    G11252787Courtesy of SUBARU OF AMERICA, INC.
  21. Disconnect the connector (A), connector (B), connector (C) and terminal (D). (Variable capacity A/C model)
  22. Remove the clip (E) and clip (F) that secure the battery cable. (Variable capacity A/C model)
    G11252788Courtesy of SUBARU OF AMERICA, INC.
  23. Disconnect the connector (A) from the EGR control valve.
  24. Remove the fuel delivery tube.
    G12391351Courtesy of SUBARU OF AMERICA, INC.
  25. Disconnect the brake booster vacuum hose (A).
  26. Remove clip (B) securing battery cable.
  27. Disengage 2 claws (C) and remove the harness protector.
    G11252790Courtesy of SUBARU OF AMERICA, INC.
  28. Disconnect the connector (A) from the tumble generator valve LH.
  29. Remove the clip securing the engine wiring harness.
    G12391353Courtesy of SUBARU OF AMERICA, INC.
  30. Remove the fuel pipe protector No. 1. (Crosstrek model)
    G12391355Courtesy of SUBARU OF AMERICA, INC.
  31. Remove the intake manifold assembly.
    • RH side
      G11252792Courtesy of SUBARU OF AMERICA, INC.
    • LH side
      G11252793Courtesy of SUBARU OF AMERICA, INC.
  32. Remove the cylinder head plate from cylinder head.
    G11252794Courtesy of SUBARU OF AMERICA, INC.
  33. Disconnect the fuel delivery pipe from the high-pressure fuel pump. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE C) .
    G11252795Courtesy of SUBARU OF AMERICA, INC.
  34. Disconnect the fuel delivery pipe (A) from the fuel pipe. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE B) .
  35. Disconnect the fuel delivery tube (B) from the fuel pipe. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE A) .
    G11252796Courtesy of SUBARU OF AMERICA, INC.
  36. When removing fuel pipe protector No. 2 (Crosstrek model)
    1. Remove the camshaft position sensor (intake LH side). Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>Camshaft Position Sensor>REMOVAL>INTAKE SIDE .
    2. Remove the fuel pipe protector No. 2.
    G12391361Courtesy of SUBARU OF AMERICA, INC.
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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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