Engine Intake System / Exhaust System: Removal & Installation Subaru BRZ ZC

Installation

1. INSTALL INTAKE MANIFOLD Install the 2 new gaskets to the intake manifold. Install the intake manifold with the 6 bolts. Standard value: T=25N.m {255kgf.cm} {18.4ft.lbf} Engage the 2 clamps. Engage the 4 connectors and connect the wire harness. Connect the fuel pump connector. Engage the clamp and connect the engine wire harness. Engage the 5 clamps and connect the battery cable. Connect the purge control solenoid valve connector. Connect the manifold absolute pressure sensor connector.
2. CONNECT VENTILATION HOSE Connect the ventilation hose.
3. CONNECT NO. 2 VACUUM HOSE (for Manual Transmission) (Refer to «INSTALLATION»(ref-619168-S33548915092014053000000) )
4. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Engage the 3 claws and install the No. 1 engine cover sub-assembly.
5. CONNECT FUEL DELIVERY PIPE SUB-ASSEMBLY Connect the No. 2 fuel vapor feed hose. Install the bolt and connect the fuel delivery pipe sub-assembly. Standard value: T=6.4N.m {65kgf.cm} {4.7ft.lbf}
6. INSTALL INTAKE MANIFOLD PROTECTOR (for Bank 2) (Refer to «UNIT INSPECTION»(ref-619185-S10105454102014053000000) )
7. INSTALL INTAKE MANIFOLD PROTECTOR (for Bank 1) (Refer to «UNIT INSPECTION»(ref-619185-S10105454102014053000000) )
8. INSTALL INJECTOR DRIVER (Refer to «INSTALLATION»(ref-619185-S04023132172014053000000) )
9. CONNECT PURGE HOSE (Refer to «UNIT INSPECTION»(ref-619185-S10105454102014053000000) )
10. CONNECT FUEL HOSE NO. 2 (Refer to «UNIT INSPECTION»(ref-619185-S10105454102014053000000) )
11. CONNECT FUEL HOSE NO. 1 (Refer to «UNIT INSPECTION»(ref-619185-S10105454102014053000000) )
12. CONNECT THROTTLE WITH MOTOR BODY ASSEMBLY Install a new gasket to the intake manifold. Install the 4 bolts and throttle with motor body assembly to intake manifold. Standard value: T=8.0N.m {82kgf.cm} {5.9ft.lbf}
13. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (Refer to «FUEL SYSTEM (FA20)»(ref-619185-S34644980412014053000000) )
14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Standard value: T=6.0N.m {61kgf.cm} {4.4ft.lbf}
15. INSPECT FUEL PUMP OPERATION AND INSPECT FOR FUEL LEAK (Refer to «PARTS LOCATION»(ref-619185-S14047327362014053000000) )
16. INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY (Refer to «UNIT INSPECTION»(ref-619157-S39322068612014053000000) )

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1. Hose removal Disconnect the hose. Release the two clamps and remove the hose from the grommet.
2. Duct removal Loosen the hose clamp. Remove the two bolts and remove the duct and chamber assembly as a unit.
3. Chamber assembly removal Loosen the hose clamp and remove the chamber assembly.

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1. Chamber assembly installation Install the chamber assembly with the hose clamp. Standard value: T=2.0N.m {20kgf.cm} {1.5ft.lbf}
2. Duct installation Install the duct and chamber assembly as a unit with the two bolts. Standard value: T=6.0N.m {61kgf.cm} {4.4ft.lbf} Install the duct with the hose clamp. Standard value: T=2.0N.m {20kgf.cm} {1.5ft.lbf}
3. Hose installation Engage the two clamps and install the hose. Insert the hose until the flange at the hose end contacts the grommet. CAUTION: When inserting the hose end, insert the hose so that the grommet rubber is not engulfed to avoid water leakage. Make sure from the passenger room side that the hose end is inserted properly. Connect the hose and install the hose.

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1. Chamber assembly check Check that air does not comes out easily from the IN side when air is blown into the chamber from the EX side.

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1. Removal of air/fuel ratio sensor (Refer to «AIR/FUEL RATIO SENSOR (FA20)»(ref-619157-S11828077772014053000000) )
2. Removal of oxygen sensor (Refer to «REMOVAL»(ref-619157-S22850346232014053000000) )
3. Removal of under cover COMPL T/M (Refer to «REMOVAL»(ref-619189-S01819081472014053000000) )
4. Removal of exhaust pipe assembly FR (Refer to «REMOVAL»(ref-619189-S01819081472014053000000) )
5. Exhaust manifold removal Remove the two nuts and remove the exhaust pipe SUB-assembly FR. Remove the gasket. Remove the six nuts and remove the exhaust manifold. Remove the two gaskets.

1. Exhaust manifold installation Install two new gaskets. Install the exhaust manifold with the six nuts. Standard value: T=30N.m {306kgf.cm} {22.1ft.lbf} Install a new gasket to the exhaust pipe SUB-assembly FR installation portion of exhaust manifold. Install the exhaust pipe SUB-assembly FR with the two nuts. Standard value: T=35N.m {357kgf.cm} {25.8ft.lbf}
2. Installation of exhaust pipe assembly FR (Refer to «INSTALLATION»(ref-619189-S26330443752014053000000) )
3. Installation of under cover COMPL T/M (Refer to «INSTALLATION»(ref-619189-S26330443752014053000000) )
4. Oxygen sensor installation (Refer to «INSTALLATION»(ref-619157-S33875808132014053000000) )
5. Installation of air/fuel ratio sensor (Refer to «INSTALLATION»(ref-619157-S00924021542014053000000) )
6. Exhaust gas leakage check Make sure that there is no exhaust gas leakage from the connections of exhaust pipes and the mounting portion of each sensor.

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1. Under cover front AL removal Remove the 12 bolts and release the seven clips to remove the under cover front AL.
2. Under cover COMPL T/M removal Remove the seven bolts to remove the under cover COMPL T/M.
3. Removal of exhaust pipe assembly FR Remove the two nuts and remove the exhaust pipe assembly FR. Remove the two nuts, two bolts and two compression springs to remove the exhaust pipe assembly CTR. Remove the bolt and remove the exhaust pipe assembly FR. Remove the two gaskets.
4. Removal of exhaust pipe assembly CTR Remove the two nuts and two bolts to remove the exhaust tail pipe assembly. Remove the cushion rubber, and remove the exhaust pipe assembly CTR. Remove the gasket.
5. Exhaust tail pipe assembly removal Remove the four cushion rubbers and remove the exhaust tail pipe assembly.
6. Tail pipe baffle removal (with tail pipe baffle) Remove the two bolts and remove the two tail pipe baffles.
7. Exhaust manifold removal (Refer to «INSTALLATION»(ref-619189-S31028650042014053000000) )
8. Removal of exhaust pipe SUB-assembly FR Front strut tower bar LH removal (Refer to «INSTALLATION»(ref-619174-S00848479992014053000000) ) Front strut tower bar RH removal (Refer to «FRONT STRUT TOWER BAR»(ref-619174-S41393927902014053000000) ) Air cleaner case SUB-assembly removal (Refer to «REMOVAL»(ref-619184-S27168385372014053000000) ) Engine wiring disconnection Release the four clamps and disconnect the engine wiring. Remove the bolt and three clamps, and then disconnect the engine wiring. Remove the 2 nuts on the engine mount. Tie the joint pipe to the front suspension crossmember SUB-assembly with rope. NOTE: This procedure is necessary to prevent the joint pipe from falling off. Install the SST to the cylinder block. SST 12281-38150, 90119-14120 Standard value: T=43N.m {439kgf.cm} {31.7ft.lbf} Release the clamp and disconnect the engine wiring. NOTE: This procedure is required to prevent the engine wiring from damaging. Install the SST to the vehicle. SST 99099AJ000, 18679AA020 CAUTION: When installing the SST to the vehicle, do not damage the engine wiring. Use a shackle with a load capacity of 250 kg (551 lb) or more. Lift the engine assembly a little bit at a time until the stud bolt of the engine mount is removed from the front crossmember. CAUTION: To avoid the damage to the SST, apply grease or lubricant to the threaded portion. To avoid the damage to the vehicle and parts, perform lifting operation a little bit at a time while checking the clearance in each part. Lift up the engine assembly until the position where the intake manifold (#4) and A/C suction hose contact lightly. Insert a cloth etc. between the intake manifold (#4) and A/C suction hose to protect the parts of them. Install the SST between engine mount and front crossmember. SST 18632AA020 Remove the rope which secures the exhaust pipe SUB-assembly FR to the front suspension crossmember SUB-assembly. Remove the exhaust pipe SUB-assembly FR.

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1. Exhaust pipe SUB-assembly FR installation Tie the exhaust pipe SUB-assembly FR to the front suspension crossmember SUB-assembly with the rope. NOTE: This operation is required to avoid dropping the exhaust pipe SUB-assembly FR.
2. Removal of SST Using the SST, lift the engine assembly. Remove the SST. SST 18632AA020 Install the two nuts of engine mounting. Standard value: T=45N.m {459kgf.cm} {33.2ft.lbf} Remove the rope which secures the joint pipe to the front suspension crossmember sub-assembly. Remove the SST from the vehicle. Remove the SST from the cylinder block. Connect the engine wiring with the clamp. Engine wiring connection Connect the engine wiring with the bolt and three clamps. Standard value: T=1.1N.m {112kgf.cm} {8.1ft.lbf} Using 4 clamps, connect the engine wire. Air cleaner case SUB-assembly installation (Refer to «FUEL SYSTEM (FA20)»(ref-619185-S34644980412014053000000) ) Front strut tower bar LH installation (Refer to «INSTALLATION»(ref-619174-S00848479992014053000000) ) Front strut tower bar RH installation (Refer to «INSTALLATION»(ref-619174-S00848479992014053000000) )
3. Exhaust manifold installation (Refer to «INSTALLATION»(ref-619189-S31028650042014053000000) )
4. Tail pipe baffle installation (with tail pipe baffle) Press in the tail pipe baffle until the tail exhaust pipe assembly plate contact shown in the illustration. Install the two tail pipe baffles with the two bolts. Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf}
5. Exhaust tail pipe assembly installation Install the exhaust tail pipe assembly with the four cushion rubbers.
6. Installation of exhaust pipe assembly CTR Install the exhaust pipe assembly CTR with the cushion rubber. Install the exhaust pipe assembly CTR to the exhaust tail pipe assembly via a new gasket with the two bolts and two new nuts. Standard value: T=48N.m {490kgf.cm} {35.4ft.lbf}
7. Installation of exhaust pipe assembly FR. Temporarily tighten the exhaust pipe assembly FR to the bracket with the bolt. Install the exhaust pipe assembly FR to the exhaust pipe assembly CTR via a new gasket with the two nuts, two bolts and two compression springs. Standard value: T=18N.m {184kgf.cm} {13.3ft.lbf} Install the exhaust pipe assembly FR to the exhaust pipe sub-assembly FR via a new gasket with the two nuts. Standard value: T=42.5N.m {433kgf.cm} {31.3ft.lbf} Finally tighten the bolt for securing the bracket of exhaust pipe assembly FR. Standard value: T=50N.m {510kgf.cm} {36.9ft.lbf}
8. Exhaust gas leakage check Make sure that there is no exhaust gas leakage from the connections of exhaust pipes and the mounting portion of each sensor.
9. Shift lever position check (transmission A/T) (Refer to «ON-VEHICLE INSPECTION»(ref-619159-S33502961152014053000000) )
10. Under cover COMPL T/M installation Install the under cover COMPL T/M with the seven bolts. Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf}
11. Under cover front AL installation Install the under cover front AL with the 12 bolts and seven clips. Standard value: Bolt A T=30N.m {306kgf.cm} {22.1ft.lbf} Standard value: Bolt B T=7.5N.m {77kgf.cm} {5.5ft.lbf}