SUBARU LEGACY 1999 Service Repair Manual

7) Remove harness bands which hold engine har-
ness onto intake manifold.
8) Remove engine harness from intake manifold.
B2M2348A
(A) Fuel injector
(B) Purge control solenoid valve
(C) Harness band
9) Remove purge control solenoid valve.
B2M2350A
10) Remove bolts which install injector pipe on
intake manifold.
B2M2783
11) Remove fuel injectors.
CAUTION:
Replace o-rings and insulators with new ones.
B2M2352
12) Loosen clamp which holds front left side fuel
hose to injector pipe.
B2M2353
13) Remove bolts which hold fuel pipes on the left
side of intake manifold.
B2M2786
14) Remove two bolts which install fuel pipes on
intake manifold.
B2M2355
40
2-7[W4B2]SERVICE PROCEDURE
4. Intake Manifold

15) Remove fuel injector pipe.
B2M2789
16) Remove fuel pipes, etc. from intake manifold.
B2M2356A
(A) Pressure regulator
(B) Fuel pipe ASSY
3. 2500 cc MODEL
1) Disconnect engine ground terminal from intake
manifold.
B2M1724
2) Disconnect EGR vacuum hose from EGR
valve.
3) Disconnect back pressure hose from pipe.
4) Disconnect BPT hoses from EGR solenoid
valve and intake manifold.
5) Remove BPT with BTP holder bracket.
6) Remove EGR valve.
B2M1727
7) Disconnect connectors from throttle position
sensor, ignition coil, fuel injectors, idle air control
solenoid valve, purge control solenoid valve and
EGR solenoid valve.
B2M0347C
(A) EGR solenoid valve
(B) Throttle position sensor
(C) Idle air control solenoid valve
(D) Purge control solenoid valve
(E) Harness band
8) Remove engine harness from intake manifold.
9) Remove idle air control solenoid valve from
intake manifold.
H2M1247
41
[W4B3]2-7SERVICE PROCEDURE
4. Intake Manifold

10) Remove throttle body from intake manifold.
B2M0157
11) Remove ignition coil.
B6M0867
12) Remove fuel pipes, etc. from intake manifold.
B2M0161D
(A) Pressure regulator
(B) Fuel pipe ASSY
13) Remove fuel injector pipes.
B2M1726
14) Remove EGR solenoid valve and purge con-
trol solenoid valve.
C: ASSEMBLY
1. 2200 cc CALIFORNIA SPEC. VEHICLES
1) Assemble fuel pipes, etc. to intake manifold.
B2M2788A
(A) Pressure regulator
(B) Fuel pipe ASSY
2) Install fuel injector pipe.
B2M2781
3) Tighten two bolts which install fuel pipes on
intake manifold.
B2M2787
42
2-7[W4C1]SERVICE PROCEDURE
4. Intake Manifold

4) Tighten two bolts which install fuel pipes on the
left side of intake manifold.
B2M2786
5) Connect left side fuel hose to injector pipe, and
tighten clamp screw.
B2M2785
6) Install fuel injectors.
CAUTION:
Always use new o-rings and insulators.
B2M2362A
(A) O-ring A
(B) Insulator A
(C) Fuel injector
(D) Insulator B
(E) O-ring B
7) Tighten bolts which install injector pipe on
intake manifold.
Tightening torque:
3.4
±0.5 N´m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)
B2M2783
8) Install purge control solenoid valve.
B2M2782A
9) Install engine harness onto intake manifold.
10) Connect connectors to fuel injectors and
purge control solenoid valve.
11) Hold engine harness by harness bands.
B2M2780A
(A) Fuel injector
(B) Purge control solenoid valve
(C) Harness band
43
[W4C1]2-7SERVICE PROCEDURE
4. Intake Manifold

12) Assemble throttle body to intake manifold.
CAUTION:
Replace gasket with a new one.
Tightening torque:
22
±2 N´m (2.2±0.2 kg-m, 15.9±1.4 ft-lb)
B2M2300
13) Connect connectors to throttle position sensor
(A), idle air control solenoid valve (B) and intake
manifold pressure sensor (C).
14) Connect air by-pass hose (D) to idle air con-
trol solenoid valve.
B2M2346A
15) Install ignition coil and ignitor assembly.
16) Connect connector to ignition coil and ignitor
assembly.
B2M2345
17) Install engine ground terminal to intake mani-
fold.
Tightening torque:
19
±1.5 N´m (1.9±0.15 kg-m, 13.7±1.1 ft-lb)
B2M2779
2. 2200 cc EXCEPT CALIFORNIA SPEC.
VEHICLES
1) Assemble fuel pipes, etc. to intake manifold.
B2M2356A
(A) Pressure regulator
(B) Fuel pipe ASSY
2) Install fuel injector pipe.
B2M2789
44
2-7[W4C2]SERVICE PROCEDURE
4. Intake Manifold

3) Tighten two bolts which install fuel pipes on
intake manifold.
B2M2355
4) Tighten two bolts which install fuel pipes on the
left side of intake manifold.
B2M2786
5) Connect left side fuel hose to injector pipe, and
tighten clamp screw.
B2M2353
6) Install fuel injectors.
CAUTION:
Always use new o-rings and insulators.
B2M2795A
(A) O-ring A
(B) Fuel injector
(C) Insulator
(D) O-ring B
7) Tighten bolts which install injector pipe on
intake manifold.
Tightening torque:
3.4
±0.5 N´m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)
B2M2783
8) Install purge control solenoid valve.
B2M2350A
9) Install engine harness onto intake manifold.
45
[W4C2]2-7SERVICE PROCEDURE
4. Intake Manifold

10) Connect connectors to fuel injectors and
purge control solenoid valve.
11) Hold engine harness by harness bands.
B2M2348A
(A) Fuel injector
(B) Purge control solenoid valve
(C) Harness band
12) Assemble throttle body to intake manifold.
CAUTION:
Replace gasket with a new one.
Tightening torque:
22
±2 N´m (2.2±0.2 kg-m, 15.9±1.4 ft-lb)
B2M2305
13) Connect connectors to throttle position sensor
(A) and idle air control solenoid valve (B).
B2M2357A
14) Install ignition coil and ignitor assembly.
15) Connect connector to ignition coil and ignitor
assembly.
B2M2345
16) Install engine ground terminal to intake mani-
fold.
Tightening torque:
19
±1.5 N´m (1.9±0.15 kg-m, 13.7±1.1 ft-lb)
B2M2779
3. 2500 cc MODEL
1) Install EGR solenoid valve and purge control
solenoid valve.
2) Install fuel injector pipes.
B2M1726
46
2-7[W4C3]SERVICE PROCEDURE
4. Intake Manifold

3) Assemble fuel pipes, etc. to intake manifold.
B2M0161D
(A) Pressure regulator
(B) Fuel pipe ASSY
4) Install ignition coil.
B6M0867
5) Assemble throttle body to intake manifold.
CAUTION:
Replace gasket with a new one.
Tightening torque:
22
±2 N´m (2.2±0.2 kg-m, 15.9±1.4 ft-lb)
B2M0157
6) Install idle air control solenoid valve to intake
manifold.
CAUTION:
Replace gasket with a new one.
Tightening torque:
6.4
±0.5 N´m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
H2M1247
7) Install engine harness onto intake manifold.
8) Connect connectors to throttle position sensor,
ignition coil, fuel injectors, idle air control solenoid
valve, purge control solenoid valve and EGR sole-
noid valve.
B2M0347C
(A) EGR solenoid valve
(B) Throttle position sensor
(C) Idle air control solenoid valve
(D) Purge control solenoid valve
(E) Harness band
9) Install EGR valve.
CAUTION:
Replace gasket with a new one.
Tightening torque:
19
±1.5 N´m (1.9±0.15 kg-m, 13.7±1.1 ft-lb)
10) Install BPT with BPT holder bracket.
47
[W4C3]2-7SERVICE PROCEDURE
4. Intake Manifold

11) Connect BPT hoses from EGR solenoid valve
and intake manifold.
12) Connect back pressure hose from pipe.
13) Connect EGR vacuum hose from EGR valve.
B2M1727
14) Connect engine ground terminal to intake
manifold.
Tightening torque:
19
±1.5 N´m (1.9±0.15 kg-m, 13.7±1.1 ft-lb)
B2M1724
D: INSTALLATION
1. 2200 cc CALIFORNIA SPEC. VEHICLES
1) Install intake manifold onto cylinder heads.
CAUTION:
Always use new gaskets.
Tightening torque:
25
±2 N´m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B2M2318
2) Connect fuel hoses.
S2M0500
3) Connect connector to oil pressure switch.
B2M1253A
4) Connect connector to crankshaft position sen-
sor.
B2M1252A
5) Connect connector to camshaft position sensor.
B2M2317B
48
2-7[W4D1]SERVICE PROCEDURE
4. Intake Manifold

6) Connect knock sensor connector.
B2M2327A
7) Connect connectors to engine coolant tempera-
ture sensor (A) and thermometer (B).
B2M0345B
8) Hold engine harness connector onto bracket.
9) Install air cleaner case stay RH and engine har-
ness bracket, and connect engine harness con-
nectors to bulkhead connectors.
B2M2315
10) Connect brake booster hose.
B2M2314
11) Connect engine coolant hose to throttle body.
B2M2299
12) Connect PCV hose (A) and pressure regulator
vacuum hose (B) to intake manifold.
B2M2313
13) Connect spark plug cords to ignition coil and
ignitor assembly.
B2M2312
14) Install fuel protector LH. (LHD model only)
B2M2754
49
[W4D1]2-7SERVICE PROCEDURE
4. Intake Manifold