Air Intake System (h4so) Subaru Impreza WRX GD/GG рестайлинг

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CAUTION

1. Wear working clothing, including a cap, protective goggles, and protective shoes during operation.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust or dirt.
4. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.
5. Be careful not to burn your hands, because each part on the vehicle is hot after running.
6. Be sure to tighten fasteners including bolts and nuts to the specified torque.
7. Place shop jacks or safety stands at the specified points.
8. Before disconnecting electrical connectors of sensors or units, be sure to disconnect the ground cable from battery.

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1. Remove the air intake duct from air cleaner case.
2. Remove bolt (A) which secures air cleaner case to stay.
3. Remove clip (B) from above the air cleaner case.
4. Remove the air cleaner element.

INSTALLATION

Install in the reverse order of removal.

Note. Fasten with the clip after inserting the lower tab of the case. For tightening torques, see COMPONENT , General Description.

INSPECTION

Replace if excessively damaged or dirty.

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1. Disconnect the ground cable from battery.
2. Disconnect the connector (A) of intake air temperature sensor.
3. Remove bolts (B) which install air cleaner case to stay.
4. Disconnect the hoses and intake duct from air cleaner case.
5. Loosen the clamp which connects air cleaner case to throttle body.
6. Remove the air cleaner case.

Install in the reverse order of removal.

Note. For tightening torques, see COMPONENT , General Description.

Inspect for cracks and loose connections.

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1. Remove the bolt which installs air intake duct A on the front side of body.
2. Remove the bolt which installs air intake duct B on the body.
3. Remove the air intake duct as a unit.

Install in the reverse order of removal.

Note. For tightening torques, see COMPONENT , General Description.

1. Inspect for cracks and loose connections.
2. Inspect that no foreign objects are mixed in the air intake duct.

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1. Remove the air intake duct, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#air-intake-system-h4so) , Air Intake Duct.
2. Remove the resonator chamber.

Install in the reverse order of removal.

Note. For tightening torques, see COMPONENT , General Description.

Inspect for cracks and loose connections.

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1. Disconnect the ground cable from battery.
2. Remove the air cleaner case, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#air-intake-system-h4so) , Air Cleaner Case.
3. Disconnect the accelerator cable (A).
4. Disconnect the cruise control cable (B), (vehicles with cruise control).
5. Disconnect the connectors from idle air control solenoid valve, throttle position sensor and pressure sensor.
6. Disconnect the air by-pass hose from the throttle body.
7. Disconnect the engine coolant hoses (A) from the throttle body.
8. Remove the bolts (B) which install throttle body to the intake manifold.

Install in the reverse order of removal.

Note. Replace the gaskets with new ones.

Tightening torque

1. Throttle body: 22 N.m (2.2 kgf-m, 15.9 ft-lb)

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1. Release fuel pressure, see «RELEASING OF FUEL PRESSURE»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#air-intake-system-h4so__releasing-of-fuel-pressure) , Fuel.
2. Open the fuel flap lid, and remove the fuel filler cap.
3. Disconnect the ground cable from battery.
4. Remove the air intake duct and air cleaner case. See «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#air-intake-system-h4so) , Air Intake Duct and «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#air-intake-system-h4so) , Air Cleaner Case.
5. Disconnect the accelerator cable (A).
6. Disconnect the cruise control cable (B), (vehicles with cruise control).
7. Remove the power steering pump and reservoir tank from bracket. Remove the resonator chamber, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#air-intake-system-h4so) , Resonator Chamber. Remove the front side V-belt. See «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#engine-mecahnical-25l-sohc) , V-belt. Remove the bolts which hold power steering pipes onto the intake manifold protector. NOTE: Do not disconnect the power steering hose. Remove the bolts which install power steering pump bracket. Disconnect the connector from the power steering pump switch. Remove the reservoir tank from the bracket by pulling it upwards. Place the power steering pump on the right side wheel apron.
8. Disconnect the spark plug cords from the spark plugs.
9. Disconnect the PCV hose from the intake manifold.
10. Disconnect the engine coolant hoses (A) from the throttle body.
11. Disconnect the brake booster hose.
12. Remove the air cleaner case stay RH and engine harness bracket, and disconnect the engine harness connectors from the bulkhead harness connectors.
13. Disconnect the connector from engine coolant temperature sensor.
14. Disconnect the knock sensor connector.
15. Disconnect the connector from crankshaft position sensor.
16. Disconnect the connector from oil pressure switch.
17. Disconnect connector from camshaft position sensor.
18. Disconnect the fuel hoses from the fuel pipes. WARNING: Do not spill fuel. Catch fuel from hoses in a container or cloth.
19. Remove the bolts which hold intake manifold onto the cylinder heads.
20. Remove the intake manifold.

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1. Install the intake manifold onto the cylinder heads. NOTE: Replace the gaskets with new ones. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
2. Connect the fuel hoses.
3. Connect the connector to the camshaft position sensor.
4. Connect the connector to the oil pressure switch.
5. Connect the connector to the crankshaft position sensor.
6. Connect the knock sensor connector.
7. Connect the connectors to the engine coolant temperature sensor.
8. Install the air cleaner case stay RH and engine harness bracket, and connect the engine harness connectors to the bulkhead connectors.
9. Connect the brake booster hose.
10. Connect the engine coolant hose (A) to the throttle body.
11. Connect the PCV hose to the intake manifold.
12. Connect the spark plug cords to the spark plugs.
13. Install the power steering pump and reservoir tank to bracket. Install the reservoir tank to bracket. Connect the connector to the power steering pump switch. Tighten the bolts which install power steering pump bracket. Tightening torque: 22 N.m (2.2 kgf-m, 15.9 ft-lb) Install the power steering pipes onto the right side intake manifold protector. Install the front side V-belt. See «INSTALLATION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#engine-mecahnical-25l-sohc) , V-belt. Install the resonator chamber. Tightening torque: 33 N.m (3.4 kgf-m, 24.6 ft-lb)
14. Connect the accelerator cable (A).
15. Connect the cruise control cable (B), (vehicles with cruise control).
16. Install the air intake duct and air cleaner case, see «INSTALLATION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#air-intake-system-h4so) , Air Intake Duct and «INSTALLATION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#air-intake-system-h4so) , Air Cleaner Case.
17. Connect the connector to the fuel pump relay.
18. Connect the battery ground cable to battery.

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1. Disconnect the engine ground terminal from the intake manifold.
2. Disconnect the connector from the ignition coil and ignitor assembly.
3. Remove the ignition coil and ignitor assembly.
4. Remove the throttle body, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#air-intake-system-h4so) , Throttle Body.
5. Remove the air assist injector solenoid valve from the intake manifold.
6. Disconnect the connector from the air assist injector solenoid valve and disconnect the air bypass hoses.
7. Remove the air assist injector solenoid valve from the intake manifold.
8. Disconnect the pressure regulator vacuum hose from the intake manifold.
9. Remove the fuel pipe protector LH.
10. Remove the fuel pipe protector RH.
11. Disconnect the connectors from the fuel injectors.
12. Disconnect the connector from the purge control solenoid valve.
13. Disconnect the air by-pass hose from the purge control solenoid valve.
14. Remove the harness bands (A) and harness bracket (B) which hold engine harness onto the intake manifold.
15. Remove the engine harness from the intake manifold.
16. Remove the purge control solenoid valve.
17. Remove the bolts which installs injector pipe on the intake manifold as shown in figure.
18. Remove the bolt which installs injector pipe on the intake manifold.
19. Remove the two bolts which hold fuel pipes on the left side of intake manifold.
20. Remove the fuel injector. Remove the fuel injector securing clip. Remove the fuel injector while lifting up the fuel injector pipe.
21. Disconnect the air by-pass hoses from the intake manifold.
22. Loosen the clamp which holds the front left side fuel hose to the injector pipe and remove the pipe.
23. Loosen the clamp which holds the front right side fuel hose to the injector pipe and remove the pipe from fuel hose.
24. Remove the fuel injector pipe.
25. Remove the bolt which installs the fuel pipes on the intake manifold.
26. Remove the fuel pipe assembly and pressure regulator, from the intake manifold.

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1. Install the fuel pipe assembly and pressure regulator, etc. to the intake manifold.
2. Tighten the bolt which installs the fuel pipes on the intake manifold. Tightening torque: 5.0 N.m (0.51 kgf-m, 3.7 ft-lb)
3. Connect the right side fuel hose to the injector pipe, and tighten the clamp screw.
4. Install the fuel injector pipe.
5. Connect the left side fuel hose to the injector pipe, and tighten the clamp screw.
6. Connect the air assist hoses.
7. Install the fuel injectors. NOTE: Replace the O-rings with new ones. NOTE: Do not forget to install the fuel injector securing clip.
8. Tighten the bolt which installs the injector pipe on the intake manifold. Tightening torque: 5.0 N.m (0.51 kgf-m, 3.7 ft-lb) Tightening torque: 19 N.m (1.9 kgf-m, 13.7 ft-lb)
9. Tighten the two bolts which install the fuel pipes on the left side of intake manifold Tightening torque: 5.0 N.m (0.51 kgf.m, 3.7 ft-lb)
10. Tighten the bolt which installs the injector pipe on the intake manifold. Tightening torque: 5.0 N.m (0.51 kgf-m, 3.7 ft-lb)
11. Install the purge control solenoid valve. Tightening torque: 19 N.m (1.9 kgf-m, 13.7 ft-lb)
12. Connect the hoses to the purge control solenoid valve. CAUTION: Connect the evaporation hose as shown in the figure.
13. Install the engine harness onto the intake manifold. Tightening torque: 16 N.m (1.6 kgf-m, 11.8 ft-lb)
14. Connect the connectors to the fuel injectors and purge control solenoid valve.
15. Hold the engine harness by harness band (A) and harness bracket (B). NOTE: Do not use harness band on harnesses where they are supposed to be protected by the fuel pipe protector.
16. Install the fuel pipe protector RH. Tightening torque: 19 N.m (1.9 kgf-m, 13.7 ft-lb)
17. Install the fuel pipe protector LH. Tightening torque: 19 N.m (1.9 kgf-m, 13.7 ft-lb)
18. Connect the pressure regulator vacuum hose to the intake manifold.
19. Install the air assist injector solenoid valve to the bracket. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
20. Install the throttle body to the intake manifold. See «INSTALLATION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#air-intake-system-h4so) , Throttle Body.
21. Install the ignition coil and ignitor assembly.
22. Connect the connector to the ignition coil and ignitor assembly.
23. Install the engine ground terminal to the intake manifold. Tightening torque: 19 N.m (1.9 kgf-m, 13.7 ft-lb)

Make sure the fuel pipe and fuel hoses are not cracked and that connections are tight.

RELEASING OF FUEL PRESSURE

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1. Disconnect the connector from the fuel pump relay.
2. Start the engine and run it until it stalls.
3. After the engine stalls, crank it for five more seconds.
4. Turn the ignition switch to OFF.

See also:
• REMOVAL
• COMPONENT
• RELEASING OF FUEL PRESSURE