Intake Induction (H4DOTC): Removal & Installation Subaru Forester SJ

INSTALLATION

Install in the reverse order of removal.

Note. Be sure to use SUBARU genuine air cleaner element depending on the engine type when replacing the air cleaner elements. Using other air cleaner element may affect the engine performance. Check that there are no foreign objects in the air cleaner case. If the protrusion of the air cleaner case (rear) is removed when removing the air cleaner element, align the protrusion of the air cleaner case (rear) to the hole on the air cleaner case (front) to install.

Scheme 933

1. Install the air cleaner case bracket to the vehicle. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
2. Install the bolt (A) and nut (B) which secure the air cleaner case (front) to the vehicle and to the air cleaner case bracket. Tightening torque: Bolt (A) 6 N.m (0.6 kgf-m, 4.4 ft-lb) Nut (B) 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
3. Set the air cleaner element to the air cleaner case (front), and install the air cleaner case (rear). NOTE: When installing the air cleaner case (rear), align the protrusion of the air cleaner case (rear) to the hole on the air cleaner case (front) to install.
4. Install the clip (B) to the air cleaner case (rear), and connect the connector (A) to the mass air flow and intake air temperature sensor.
5. Tighten the clamp which secures the air intake boot to the air cleaner case (rear). Tightening torque: 2.5 N.m (0.3 kgf-m, 1.8 ft-lb)
6. Set the front mud guard RH to the vehicle, and install the clips which secure the front mud guard RH.
7. Install the engine control module (ECM). < Ref. to «INSTALLATION»(ref-662119-S42127221602014101300000) , Engine Control Module (ECM). >
8. Install the air intake duct (rear). < Ref. to «INSTALLATION»(ref-662121-S35607443062014101300000) , Air Intake Duct. >
9. Connect the battery ground terminal.

Install in the reverse order of removal.

Note. When installing the air intake boot to the vehicle, pay attention to the mounting hole position, and align the protrusion for stopping rotation of cushion to the cutout portion on the turbo duct.

Scheme 934

Tightening torque

18 N.m (1.8 kgf-m, 13.3 ft-lb)

Tightening torque

7.5 N.m (0.8 kgf-m, 5.5 ft-lb)

Tightening torque

2.5 N.m (0.3 kgf-m, 1.8 ft-lb)

Install in the reverse order of removal.

REMOVAL

Remove the turbo charger and front exhaust pipe as a unit. Refer to "Front Exhaust Pipe" for the removal procedure. < Ref. to REMOVAL , Front Exhaust Pipe. > < Ref. to DISASSEMBLY , Front Exhaust Pipe. >

Refer to "Front Exhaust Pipe" for the installation procedure. < Ref. to INSTALLATION , Front Exhaust Pipe. > < Ref. to ASSEMBLY , Front Exhaust Pipe. >

Scheme 935

Scheme 936

Scheme 937

Scheme 938

Scheme 939

1. Remove the union screw pipe assembly from the turbocharger.
2. Remove the turbocharger pipe from the turbocharger.
3. Remove the air control hose from the turbocharger.
4. Remove the stud bolt from the turbocharger.
5. Remove the exhaust stay from the turbocharger.

Scheme 940

1. Install the exhaust stay to the turbocharger. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
2. Attach the stud bolts to the turbocharger. Tightening torque: 14.7 N.m (1.5 kgf-m, 10.8 ft-lb)
3. Install the air control hose to the turbocharger.
4. Install the turbocharger pipe to the turbocharger. NOTE: Use a new gasket. Tightening torque: 31.5 N.m (3.2 kgf-m, 23.2 ft-lb)
5. Install the union screw pipe assembly to the turbocharger. NOTE: Use a new gasket. Tightening torque: T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) T2: 16 N.m (1.6 kgf-m, 11.8 ft-lb)

Scheme 941

Scheme 942

1. Remove the front exhaust pipe. < Ref. to «REMOVAL»(ref-662147-S11833000002014101300000) , Front Exhaust Pipe. >
2. Remove the exhaust cover.
3. Remove the vacuum control hose (B) from the waste gate actuator (A) of the turbocharger, and connect the Mighty Vac to the waste gate actuator (A).
4. Pressurize slowly with the Mighty Vac, and check the pressure when the control rod stroke (D) becomes 1±0.15 mm (0.0394±0.0059 in). If it is not within the standard, replace the turbocharger assembly. CAUTION: Do not pressurize over 112.7 kPa (1.15 kgf/cm 2 , 16.34 psi) to prevent damaging the waste gate actuator. Operating pressure (control rod stroke 1±0.15 mm (0.0394±0.0059 in)): Standard 84.0 - 88.0 kPa (0.86 - 0.90 kgf/cm 2 , 12.18 - 12.76 psi)
5. After inspection, install the related parts in the reverse order of removal. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

Refer to "Scavenge Pump" for removal procedure of scavenge pump. < Ref. to REMOVAL , Scavenge Pump. >

Refer to "Scavenge Pump" for installation procedure of scavenge pump. < Ref. to INSTALLATION , Scavenge Pump. >

Install in the reverse order of removal.

Tightening torque

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

Scheme 943

Scheme 944

1. Check that the air by-pass valve has no deformation, cracks or other damages.
2. Connect the Mighty Vac to the nipple (A) of the air by-pass valve.
3. Using the Mighty Vac, generate the vacuum pressure to -93.3 kPa (-0.95 kgf/cm 2 , -13.5 psi). Check that the Mighty Vac gauge needle holds 10 seconds without falling by -92.6 kPa (-0.94 kgf/cm 2 , -13.4 psi).
4. Set a dial gauge to the end of valve rod of the air by-pass valve.
5. Using the Mighty Vac, generate the negative pressure, and check the pressure when dial gauge needle (valve stroke) shows 0.5 mm (0.02 in). If it is not within the standard, replace the air by-pass valve. Opening pressure (valve stroke 0.5 mm (0.02 in)): Standard -13.3 - -21.3 kPa (-0.14 - -0.22 kgf/cm 2 , -1.93 - -3.09 psi)

The resonator chamber and air cleaner case are integrated into one unit; therefore, refer to "Air Cleaner Case" for removal procedure. < Ref. to REMOVAL , Air Cleaner Case. >

The resonator chamber and air cleaner case are integrated into one unit; therefore, refer to "Air Cleaner Case" for installation procedure. < Ref. to INSTALLATION , Air Cleaner Case. >