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Intake Induction (H4DOTC): Other Subaru Forester SJ

Mechanical 6 illustrations ~800 words

CAUTION

  1. Prior to starting work, pay special attention to the following: Always wear work clothes, a safety cap, protective shoes. Additionally, wear a helmet, protective goggles, etc. if necessary. Protect the vehicle using a seat cover, fender cover, etc. Prepare the service tools, clean cloth, containers to catch grease and oil, etc.
  2. Vehicle components are extremely hot immediately after driving. Be wary of receiving burns from heated parts.
  3. When performing a repair, identify the cause of trouble and avoid unnecessary removal, disassembly and replacement.
  4. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery.
  5. Always use the jack-up point when the shop jacks or rigid racks are used to support the vehicle.
  6. Remove contamination including dirt and corrosion before removal, installation, disassembly or assembly.
  7. Keep the removed parts in order and protect them from dust and dirt.
  8. All removed parts, if to be reused, should be reinstalled in the original positions with attention to the correct directions, etc.
  9. Bolts, nuts and washers should be replaced with new parts as required.
  10. Be sure to tighten the fasteners including bolts and nuts to the specified torque.

GENERAL TOOL

TOOL NAMEREMARKS
TORX® socket E10Used for disassembling and assembling the turbocharger.
Mighty VacUsed for checking waste gate actuator and air by-pass valve.

Scheme 948

Scheme 948: REMOVAL
Scheme 948: REMOVAL

Scheme 949

Scheme 949
Scheme 949
  1. Remove the clip (A) from the air cleaner case (rear).
  2. Open the air cleaner case, and remove the air cleaner element.

INTAKE DUCT NO. 1

  1. Install the intake duct No. 1 to the turbocharger. NOTE: Use new O-rings. Be careful not to pinch the O-ring. Check that the air by-pass valve is firmly inserted into the intake duct No. 1. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
  2. Engage the clip which secures the air by-pass valve to the intake duct No. 1, and install the air intake boot to the intake duct No. 1. Tightening torque: 2.5 N.m (0.3 kgf-m, 1.8 ft-lb)
  3. Connect the PCV pipe (A) to the intake duct No. 1, and connect the vacuum control hose (B) to the wastegate control solenoid valve.
  4. Connect the connector to the wastegate control solenoid valve.
  5. Install the under cover. < Ref. to «INSTALLATION»(ref-662136-S09037710362014101300000) , Front Under Cover. >
  6. Lower the vehicle.
  7. Connect the vacuum hose to the vacuum pipe.
  8. Install the air intake duct (rear). < Ref. to «INSTALLATION»(ref-662121-S35607443062014101300000) , Air Intake Duct. >
  9. Connect the battery ground terminal.
  10. Install the collector cover.

INTAKE DUCT NO. 2

  1. Set the air by-pass valve to the intake duct No. 1, and install the intake duct No. 2 to the intake manifold.
  2. Install the bolt which secure the intake duct No. 2 to the turbocharger. NOTE: Use new O-rings. Be careful not to pinch the O-ring. Check that the air by-pass valve is firmly inserted into the intake duct No. 1. Tightening torque: 16 N.m (1.6 kgf-m, 1.8 ft-lb)
  3. Lift up the vehicle.
  4. Engage the clip which secures the air by-pass valve to the intake duct No. 1.
  5. Connect the PCV pipe (A) and vacuum hose (B) to the intake duct No. 1, and connect the vacuum hose (C) to the air by-pass valve.
  6. Install the under cover. < Ref. to «INSTALLATION»(ref-662136-S09037710362014101300000) , Front Under Cover. >
  7. Lower the vehicle.
  8. Install the radiator sub fan and fan motor assembly. < Ref. to «INSTALLATION»(ref-662123-S16701728782014101300000) , Radiator Sub Fan and Fan Motor. >
  9. Install the intercooler. < Ref. to «INSTALLATION»(ref-662121-S02050373282014101300000) , Intercooler. >
  10. Install the air intake duct (rear). < Ref. to «INSTALLATION»(ref-662121-S35607443062014101300000) , Air Intake Duct. >
  11. Connect the battery ground terminal.
  12. Install the collector cover.

Scheme 950

Scheme 950: INTAKE DUCT NO. 3
Scheme 950: INTAKE DUCT NO. 3
  1. Align the triangle mark (A) on the intake duct No. 3 to the rib (B) on the throttle body, and install the intake duct No. 3 to the throttle body. NOTE: Use a new insulator. Apply a thin coat of SUBARU PS fluid (K0515YA000) or liquid paraffin to the inner periphery of the insulator. When inserting the intake duct No. 3 to the throttle body, be careful that the insulator is not turned over. Tightening torque: 3 N.m (0.3 kgf-m, 2.2 ft-lb)
  2. Install the clip which secures the brake booster vacuum hose to the intake manifold.
  3. Install the intercooler. < Ref. to «INSTALLATION»(ref-662121-S02050373282014101300000) , Intercooler. >
  4. Connect the battery ground terminal.
  5. Install the collector cover.

Remove the vacuum hose and wastegate control solenoid valve from the intake duct.

Scheme 951

Scheme 951: INTAKE DUCT NO. 1
Scheme 951: INTAKE DUCT NO. 1

Remove the air by-pass valve from the intake duct No. 2.

Scheme 952

Scheme 952: INTAKE DUCT NO. 2
Scheme 952: INTAKE DUCT NO. 2

INTAKE DUCT NO. 3

Remove the insulator from the intake duct No. 3.

Scheme 953

Scheme 953: INTAKE DUCT NO. 3
Scheme 953: INTAKE DUCT NO. 3

Install the vacuum hose and wastegate control solenoid valve to the intake duct No. 1.

Note. Use new O-rings. When tightening the boost control solenoid valve, check that it is securely seated.

Tightening torque

2.8 N.m (0.3 kgf-m, 2.1 ft-lb)

Assemble in the reverse order of disassembly.

Tightening torque

3 N.m (0.3 kgf-m, 2.2 ft-lb)

Assemble in the reverse order of disassembly.

Note. Use a new insulator.

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