INTAKE MANIFOLD

FUEL INJECTION (FUEL SYSTEMS)

3. Intake Manifold (2) Disconnect the power steering switch con-

nector.
A: REMOVAL
1) Release the fuel pressure. <Ref. to FU(STi)-45,
RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Open the fuel filler lid and remove the fuel filler
cap.
3) Disconnect the ground cable from battery.

FU-00017

(3) Remove the bolts which secure the power

steering pipe brackets to the intake manifold.
NOTE:
Do not disconnect the power steering hose.

FU-00009

4) Lift up the vehicle.

5) Remove the under cover.
6) Drain the engine coolant about 3.0 2 (3.2 US qt,
2.6 Imp qt).

FU-00018

(4) Remove the bolts which secure the power

steering pump bracket.

FU-00016

7) Remove the air cleaner upper cover and air in-

take boot. <Ref. to IN(STi)-8, REMOVAL, Air
Cleaner.>
8) Remove the air cleaner element.
9) Remove the intercooler. <Ref. to IN(STi)-11,
REMOVAL, Intercooler.> FU-00019
10) Remove the coolant filler tank. <Ref. to
CO(H4DOTC)-32, REMOVAL, Coolant Filler (5) Remove the power steering tank from the
Tank.> bracket by pulling it upward.
11) Remove the power steering pump.
(1) Remove the front side V-belt.
<Ref. to ME(STi)-41, REMOVAL, V-belt.>

FU-00020

FU(STi)-14
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

(6) Place the power steering pump on the right 15) Disconnect the pressure hose from the intake
side wheel apron. duct.

FU-00021 FU-00024

12) Disconnect the emission hose (A) and connec- 16) Disconnect the engine harness connectors
tor (B) from the PCV hose assembly. from the bulkhead harness connectors.

(A)
(B)

FU-01032 FU-00025

13) Disconnect the engine coolant hoses from the

throttle body.

FU-00026

17) Disconnect the connectors from the engine

FU-01074
coolant temperature sensor (A), oil pressure switch
14) Disconnect the brake booster hose. (B) and crankshaft position sensor (C).

(A)
(B)

(C)

FU-00023 FU-00027

FU(STi)-15
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

18) Disconnect the knock sensor connector. 22) Disconnect the fuel delivery hose, return hose
and evaporation hose.
CAUTION:
• Do not spill fuel.
• Catch fuel from hoses in a container or cloth.

FU-00028

19) Disconnect the connector from the camshaft

position sensor.

FU-00032

23) Remove the bolts which secure the intake man-

ifold to the cylinder heads.

FU-01038

20) Disconnect the connector from the ignition coil.

FU-01039

24) Remove the intake manifold.

B: INSTALLATION
1) Install the intake manifold onto cylinder heads.
NOTE:
Always use new gaskets.
FU-00030 Tightening torque:
21) Disconnect the engine harness fixed by clip (A) 25 N·m (2.5 kgf-m, 18.1 ft-lb)
from the bracket.

(A)

FU-01039
FU-00031

FU(STi)-16
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

2) Connect the fuel delivery hose, return hose and 6) Connect the connector to the ignition coil.
evaporation hose.

FU-00030
FU-00032
7) Connect the engine harness with clip (A) to the
3) Connect the connector to the oil pressure switch bracket.
(B), crankshaft position sensor (C) and engine
coolant temperature sensor (A).

(A)
(A)
(B)

(C)

FU-00031

FU-00027
8) Connect the engine harness connector to the
bulkhead harness connectors.
4) Connect the connector to the knock sensor.

FU-00025
FU-00028

5) Connect the connector to the camshaft position

sensor.

FU-00026

FU-01038

FU(STi)-17
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

9) Connect the brake booster vacuum hose. 13) Install the power steering pump.
(1) Install the power steering tank on the brack-
et.

FU-00023

10) Connect the engine coolant hoses to the throt- FU-00020

tle body.
(2) Connect the connector to the power steering
pump switch.

FU-01074

11) Connect the emission hose (A) and connector FU-00017

(B) to the PCV hose assembly.
(3) Install the power steering pump, and tighten
the bolts.
Tightening torque:
22 N·m (2.2 kgf-m, 15.9 ft-lb)

(A)
(B)

FU-01032

12) Connect the pressure hose to the intake duct.

FU-00019

(4) Install the power steering pipe brackets on

the intake manifold RH.

FU-00024

FU-00018

FU(STi)-18
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

(5) Install the front side V-belt. 2) Remove the engine ground terminal from the in-
<Ref. to ME(STi)-41, INSTALLATION, V-belt.> take manifold.
14) Install the coolant filler tank. <Ref. to
CO(H4DOTC)-32, INSTALLATION, Coolant Filler
Tank.>
15) Install the intercooler. <Ref. to IN(STi)-11, IN-
STALLATION, Intercooler.>
16) Install the air cleaner element.
17) Install the air cleaner upper cover and air intake
duct as a unit. <Ref. to IN(STi)-8, INSTALLATION,
Air Cleaner.>
18) Connect the connector to the fuel pump relay.
FU-01041

ME-00649

19) Connect the battery ground cable to battery. FU-01042

20) Lift up the vehicle. 3) Disconnect the connector from the throttle posi-
21) Install the under cover. tion sensor (A) and manifold absolute pressure
22) Fill the engine coolant. <Ref. to CO(H4DOTC)- sensor (B).
17, FILLING OF ENGINE COOLANT, REPLACE-
MENT, Engine Coolant.> (B)

C: DISASSEMBLY
1) Remove the fuel pipe protector RH.
(A)

FU-01073

4) Remove the throttle body from the intake mani-

fold.

FU-01040

FU-01075

FU(STi)-19
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

5) Disconnect the connector from the fuel injector. 10) Disconnect the evaporation hose and purge
valve from the intake manifold.

FU-01043
FU-01045
6) Disconnect the connector from the tumble gen-
erator valve actuator. 11) Remove the two bolts which hold the fuel pipes
on the left side of intake manifold.

FU-00616
FU-00043
7) Disconnect the connector from the tumble gen-
erator valve sensor. 12) Remove the bolt which hold the fuel injector
pipe onto intake manifold.
• LH SIDE

FU-00617

8) Disconnect the connector from the purge control FU-01046

solenoid valve.
9) Remove the purge control solenoid valve.

FU-01047
FU-01044

FU(STi)-20
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

• RH SIDE 16) Loosen the clamp which holds the right side
fuel hose to injector pipe, and then remove the pipe
from clamp.

FU-01048

FU-01051

17) Remove the bolts which install the fuel pipe on

intake manifold.

FU-01049

13) Remove the harness bracket which holds the

engine harness onto intake manifold.
FU-01052

18) Remove the fuel pipe assembly and pressure

regulator from the intake manifold.
19) Remove the intake duct from the intake mani-
fold.

FU-00049

14) Remove the engine harness from the intake

manifold.
15) Loosen the clamp which holds the front left side
fuel hose to injector pipe, and then remove the pipe
from clamp. FU-01076

20) Remove the tumble generator valve assembly

from the intake manifold.

FU-01050

FU-00053

FU(STi)-21
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

D: ASSEMBLY 5) Connect the left side fuel hose to injector pipe,

and tighten the clamp screw.
NOTE:
Replace the gasket with a new one.
1) Install the tumble generator valve assembly to
the intake manifold.
Tightening torque:
8.25 N·m (0.84 kgf-m, 6.1 ft-lb)

FU-01050

6) Install the fuel injector pipe RH.

7) Connect the right side fuel hose to injector pipe,
and tighten the clamp screw.

FU-00053

2) Install the air intake duct to the intake manifold.

Tightening torque:
19 N·m (1.94 kgf-m, 13.7 ft-lb)

FU-01051

8) Install the engine harness to the intake manifold.

9) Install the harness bracket which holds the en-
gine harness onto intake manifold.
Tightening torque:
19 N·m (1.94 kgf-m, 13.7 ft-lb)
FU-01076

3) Install the fuel pipe assembly and pressure reg-

ulator to the intake manifold.
Tightening torque:
4.9 N·m (0.5 kgf-m, 3.6 ft-lb)

FU-00049

FU-01052

4) Install the fuel injector pipe LH.

FU(STi)-22
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

10) Tighten the bolts which install the fuel injector 11) Tighten the two bolts which install the fuel pipes
pipe onto intake manifold. on the left side of intake manifold.
Tightening torque: Tightening torque:
19 N·m (1.94 kgf-m, 13.7 ft-lb) 4.9 N·m (0.5 kgf-m, 3.6 ft-lb)
• LH SIDE

FU-00043
FU-01046
12) Connect the evaporation hoses to the purge
valve.
NOTE:
Connect the evaporation hoses as shown in the fig-
ure.

(A)
(B)
FU-01047

• RH SIDE
(C)

(D)
FU-01057

(A) To intake duct

(B) To intake manifold
(C) To purge control solenoid valve
(D) To fuel pipe ASSY

13) Connect the evaporation hose and purge valve

FU-01048 to the intake manifold.

FU-01045
FU-01049

FU(STi)-23
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

14) Install the purge control solenoid valve. 18) Connect the connector to the tumble generator
valve actuator.
Tightening torque:
16 N·m (1.6 kgf-m, 11.8 ft-lb)

FU-00616

FU-01044 19) Connect the connector to the fuel injector.

15) Connect the hoses to the purge control sole-
noid valve.
NOTE:
Connect the evaporation hoses as shown in the fig-
ure.

FU-01043

20) Install the throttle body to the intake manifold.

NOTE:
(A) Replace the gasket with a new one.

(B)
Tightening torque:
FU-00054 8 N·m (0.8 kgf-m, 5.8 ft-lb)
(A) To purge valve
(B) To intake manifold

16) Connect the connector to the purge control so-

lenoid valve.
17) Connect the connector to the tumble generator
valve sensor.

FU-01075

FU-00617

FU(STi)-24
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

21) Connect the connector to the throttle position E: INSPECTION

sensor (A) and manifold absolute pressure sensor Make sure the fuel pipe and fuel hoses are not
(B). cracked and the connections are tightened.
(B)

(A)

FU-01073

22) Install the engine ground terminal to the intake

manifold.
Tightening torque:
19 N·m (1.94 kgf-m, 13.7 ft-lb)

FU-01041

FU-01042

23) Install the fuel pipe protector RH.

Tightening torque:
19 N·m (1.94 kgf-m, 13.7 ft-lb)

FU-01040

FU(STi)-25