2021 Subaru Crosstrek HybridFACTORY OEM SERVICE PROCEDURE

Intake Manifold Assembly: Installation

  1. Connect the fuel delivery tube (B). Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO(HEV))>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE A) .
  2. Connect the fuel delivery pipe (A). Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO(HEV))>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE B) .
    G13230813Courtesy of SUBARU OF AMERICA, INC.
  3. Connect the fuel delivery pipe. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO(HEV))>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE C) .
    G13230812Courtesy of SUBARU OF AMERICA, INC.
  4. Install the cylinder head plate.
    G13230811Courtesy of SUBARU OF AMERICA, INC.
  5. Set a new gasket and install the intake manifold assembly.
    NOTE: Be careful not to let the engine wiring harness be caught by the parts.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.4 ft-lb)

    G13230810Courtesy of SUBARU OF AMERICA, INC.
  6. Install the fuel delivery tube.
    G13230809Courtesy of SUBARU OF AMERICA, INC.
  7. Connect the connector (A) and install the clip.
    G13230808Courtesy of SUBARU OF AMERICA, INC.
  8. Install the fuel pipe protector No. 1.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14.0 ft-lb)

  9. Install the HV air conditioning wire with the clip (A).
    G13230807Courtesy of SUBARU OF AMERICA, INC.
  10. Set the engine wiring harness and secure the engine wiring harness to the bracket with the claw.
    G13230055Courtesy of SUBARU OF AMERICA, INC.
  11. Connect the battery positive terminal. Ref. to REPAIR CONTENTS>REPAIR CONTENTS>NOTE>BATTERY .
  12. Install the engine wiring harness to the clip (C), and connect the connector (B) to the main fuse box.
  13. Connect connector (A) to ECM. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO(HEV))>ENGINE CONTROL MODULE (ECM)>INSTALLATION .
    G13230054Courtesy of SUBARU OF AMERICA, INC.
  14. Install the clips.
  15. Install the fuel delivery tube clamp (B).
  16. Connect the connector (A).
    G13230804Courtesy of SUBARU OF AMERICA, INC.
  17. Secure the fuel pipe with the bolt.

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

  18. Connect the evaporation hose (D).
  19. Connect the connector (B) and install the clip (C).
  20. Connect the connector (A).
    G13230803Courtesy of SUBARU OF AMERICA, INC.
  21. When the engine coolant (engine side) is not drained before removing the intake manifold assembly
    1. Install the throttle body. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO(HEV))>THROTTLE BODY>INSTALLATION .
    2. Install the EGR control valve. Ref. to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DO(HEV))>EGR CONTROL VALVE>INSTALLATION .
    3. Install the preheater hose.
    G13230801Courtesy of SUBARU OF AMERICA, INC.
  22. When the engine coolant (engine side) is drained before removing the intake manifold assembly
    1. Connect the preheater hose (B) and connect the connector (A).
      G13230802Courtesy of SUBARU OF AMERICA, INC.
    2. Install the EGR control valve. Ref. to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DO(HEV))>EGR CONTROL VALVE>INSTALLATION .
  23. Attach the PCV hose No. 1. Ref. to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DO(HEV))>PCV HOSE>INSTALLATION>PCV HOSE NO. 1 .
  24. Install the collector cover. Ref. to INTAKE (INDUCTION) (H4DO (EXCEPT FOR HEV))>COLLECTOR COVER>INSTALLATION .
  25. Install the air intake boot. Ref. to INTAKE (INDUCTION) (H4DO (EXCEPT FOR HEV))>AIR INTAKE BOOT>INSTALLATION .
  26. Connect the battery ground terminal. Ref. to REPAIR CONTENTS>REPAIR CONTENTS>NOTE>BATTERY .
  27. If the fuel delivery tube is disconnected, perform the following work.
    1. Install the fuel filler cap, and close the fuel filler lid.
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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.