EJ-Series Intake Manifold Assembly & Install

in today's video I'm gonna walk you guys through all the steps to reassemble that factory intake manifold assembly it's not just the illumine intake manifold do you need to worry about there's actually a bunch of components you need to install on this intake manifold and you need to make sure you do it in a certain order and in today's video I'm gonna walk you guys through all the steps to reassemble that intake manifold assembly and I'm gonna go ahead and install it on my EJ 205 engine thanks so much for checking out the video guys and thanks so much for joining me and my little super rolling shop here in Northern California my name is Luke and this is a super only show this is my little super only shop it's a DIY Subaru channel it's a channel where all I do is super build and race new boo vehicles and motorsport events it's a DIY themed channel where I walk you guys through the steps to get your suit back on the road and hopefully do a little racing on your own so thanks for checking out the video guys I really appreciate it okay guys there's actually a bunch of steps in this process and a bunch of different components meaning to install onto this intake manifold so to make it a little bit easier and help us visualize all the steps are involved in this process I actually went ahead and grabbed my white board and put six key steps up on that white board and before we get started assembly a Cintiq manifold assembly I'm gonna walk you guys through each one of those six steps the first step is @tg v's and that stands for tumbled generator valves you're actually gonna install the tumble generator valves with new gaskets on this intake manifold first and then the second step is that air intake at this point it's a good idea to go ahead and bolt in that air intake and then the third step here is the fuel line's the hard fuel line's actually bolt up to the underside of the intake manifold and the number four is wiring harness in addition to the fuel lines you also have the wiring harness that's installed underneath the intake manifold you need to make sure you install this wiring harness after you've done these first three steps and number five is actually installing the fuel rails and injectors I'm going to show you guys how to do that when we get there and then number six is installing all those evaporative lines these are actually all the emissions lines that capture all the vapors in your fuel system there's a bunch of these evap lines and a little purge solenoid you have to install on this intake manifold if you want to be completely compliant if you wanna have all the factory emissions components installed on your engine step one is installing the TVs or the tumble generator vowels now I've actually cleaned up these TVs by spraying them with some aluminum mag wheel cleaner and then scrubbing them with a wire brush and then rinsing them with clean water and this is basically what my final finish is it's not perfect it's not anywhere near as good as media blasting but if you're at home and all you got is a little bit of cleaner and a wire brush this is actually a pretty decent finish and it's a hell of a lot better then leaving it all grimy and greasy and all full of that white oxidation that was caked all over it before so this sucker looks a hell of a lot better and it's gonna look really nice against that red wrinkled coat paint it's on the intake manifold now anytime you can install a set of TVs you always want to make sure you use new set of gaskets these are set of gaskets from grim speed I'm using these plenty of times they're high-quality incidentally I'll point out those gaskets often come in a set I actually have two sets we only need one set when you're connecting those TVs to your intake manifold then go ahead and grab that gasket and line it up with those studs and drop it down on it and install it on your intake manifold and when you go to install this TGV you're gonna notice there's actually two studs that'll help you align it with that intake manifold so start with those two studs there on the outside of those TVs first ones right here and the other ones right here so you can start with lining these studs up and putting those through the holes and using the little nuts which I believe we're a little ten millimeter nuts then for these other four holes right here here here and here those are actually gonna use little bolts I actually have a box full of new bolts is a zinc plated bolt it's just as good as that factory OEM quality bolt it's the same grade or higher and it's gonna look great without new red intake metal paint so go ahead and line this sucker up and drop it on those studs and get a couple of those bolts and get that started as well I'll get those little nuts on I'm not gonna do anything super tight yet I'm just gonna go ahead and snot everything down you know torque it down at the end when I have both these suckers installed all right and there's a first TGV that suckers completely installed imma go ahead and move over to the other side so it's good practice and you're bolting anything up to housing machine surface you start from the inside and work your way out all right boom go ahead get that last nut installed you're good to go okay these little suckers you only torque these suckers down to about six point one foot-pounds so go ahead and grab your torque wrench and torque that sucker down to about six point one foot-pounds all right we are done with the first step the TGV so I'm gonna go ahead pull a check there I'll move on to the next step which is installing the air intake okay guys to install the air intake we're actually gonna flip this intake manifold around that way it's kind of the same orientation as it is in the engine bay and another thing I want to show you guys is this really quick and easy fix that I came up with to repair a rip and your intake manifold it's a really common thing happens right here with a hose clamp is installed that hose clamp actually has a bit of a serrated edge on it and over time the pressure and a little bit of vibration with that hose clamp can actually wear a rip or put a hole right that soft rubber point where it slips over your turbo inlet there's actually a hole that developed from that hose clamp that was installed on it and this is actually my fix it's a simple and inexpensive repair for torn air intake and all it is is a silicone bracelet it's about a half-inch wide and it's got an eight inch circumference this little sucker actually fits perfectly over that air intake when we put a hose clamp over the silicone it actually helps cinch the silicone down over the hole or the rip that's what the idea here is is you basically grab that silicone band and you stall it right over that spot with a hose clamp usually cinches down just like this this half inch wide hose clamp is actually the perfect width to sit in that little groove the hose clamps it's and in addition to sealing a ripped or torn air intake this little silicone band will actually prevent a good air intake from developing a rip or a hole at a later time so I gotta be honest guys getting when these little silicone bands is something anybody should do on any car it's really running any of these air intakes that has a soft rubber material for that connection point to the turbo because it's really common for those hose clamps to cut through them and develop a hole in them and as you can see they make them black - now I'm gonna notice it once everything's reinstalled basically this is a really simple and easy step for the air intake already gonna do is line up this mark right here you can put one little bolt and you're just gonna kind of loosely thread that bolt in we're not gonna crank it down at all right now but we do want to have this air intake lightly bolted down and like I said this is a pretty simple process just go ahead and loosely install that bolt to hold that air intake in place while we go ahead and move on to the next steps okay we are done with step number two install that air intake so I'm gonna put a check by that sucker I'll move on to step number three which is installing those hard fuel lines now that we have these TVs installed on this awesome red intake manifold and we use that new hardware to install it we can actually move on to the next step which is installing these hard lines these steel hard lines actually bolt up to the bottom of this intake manifold the first step is that you're going to start with its left fuel rail and fuel line assembly install the sucker first and then lightly snug down the bolts that'll be the first step I'm gonna walk you guys through that right now okay to install this left-side fuel rail assembly you're gonna start by weaving this side of the hard line around to the backside of this intake manifold like this then go ahead and grab your bolts and install them through those holes and as you guys you probably noticed I'm using a lot of new hardware on this engine these bolts are new bolts and they've been zinc coated which is a really good treatment to resist surface corrosion so I'll go ahead and install these nice brand new zinc coated bolts and I'll just kind of Snug them down lightly okay and bam that first left-side fuel rail is completely installed and we'll go ahead and move on to the rest of these fuel line assemblies and that right side fuel rail okay so next we're gonna install the rest of these fuel lines in that right side fuel rail assembly and if you don't know the steps to install this whole assembly as one unit it can definitely be a pain in the ass and it could easily end up scratching that brand-new paint job on an intake manifold well tell you guys right now it's actually not that tricky you can definitely install this whole assembly on that intake manifold with very little scratches and here's a trick you're gonna start by weaving this side through this portion of the intake manifold so this hole right here lines up with a bolt location right here and your intake manifold that's the first step and to do that you want to go ahead and grab your intake manifold and lift it up to almost a near vertical position and then weave this portion through that little gap right here I'm gonna go ahead and do that right now lift that intake manifold up gently getting oriented right and it should pop right up in there and once it pops in there we'll go ahead and work on the right side fuel rail okay once you have to get those fuel lines through that gap on the left side you can go ahead and move over to the fuel rail on your right side now this sucker might also seem kind of complicated but if you walk through the right steps it's actually not that difficult we just gotta get this fuel rail so then bolt down to these two holes right here and to do that you want to go ahead lift your fuel rail up and then go ahead pull that fuel line and fuel rail assembly over to the front of the intake manifold and just kind of slip it around up and over those little ports for your fuel injectors and she'll go slip this thing over and line it up with those holes so you can put a bolt in there and hold it in place just like that and I'll go ahead and grab one those new zinc-plated bolts and I'll loosely install it to hold everything in place okay the next thing you want to do is go ahead and attach these two fuel rail assemblies you want to work this hose over this little barbed hard line and connect it with that hose clamp you might have to loosen up those bolts quite a bit to get enough play in there so you can slide that rubber end over that hard line so go ahead and get that sucker connected before we move on to the next step you want to make sure you can feel the little ridge from the barb on that hard line that way you can put the hose clamp on the backside of that little Ridge so hose comfortable right here and a little Ridge from the barb on the hard lines right here okay next I'll go ahead and put two bolts on the bottom of the steel rails right here right here and then it'll be completely bolted up to the intake manifold if these little holes aren't quite lined up you may need to adjust how far the hardline pushes into that rubber fuel line that connects it to assemblies okay now we have both these bolts installed we actually have the complete fuel rail and fuel line assembly reinstalled on this intake manifold so we can go ahead and move on to the next step which is installing that wiring harness all right when we finished step number three so I can go ahead and grab my dry erase marker and I'll put a check by step number three okay moving right along moving on the step number four which is installing that wiring harness okay guys we're making great progress and this is the next step we're gonna install this section of the wiring loom or the wiring harness this is basically the portion of your wiring harness that connects to all the sensors that are on your engine and to install this sucker on your intake manifold assembly basically what you want to look for is this plastic section right here this is actually a protectable hard cover for wiring harness it actually helps protect the wires from soaking in the heat from your engine so you definitely wanna retain this plastic part and don't throw it away it also helps you orient the wiring harness when you install it on these intake manifolds so take a look the curves and the bends in this little section and then go ahead and line up the holes with this little cover with the holes on the bottom of that intake manifold we're gonna start by flipping that APIC manifold assembly over so we can get access to the bottom of it okay then you want to grab that wiring harness and lay it down there's actually only one way the lines up with all those holes so line up those holes and go ahead and install those bolts all right we finished installing wiring harness I'm going to bust out my dry erase marker I'm gonna mark off that step step number four is actually done so we can now move on to step number five which is installing those fuel injectors I've actually already installed the fuel rails so there's no need to worry about those okay guys so the next step is to install these fuel injectors in these fuel rails and the first thing when to mention is anytime you can store your fuel injectors strongly in some kind of plastic bag it's dust proof because these fuel injectors really need to be completely free of any contamination when you install them now if you take a closer look at these fuel injectors you're gonna see there's actually three rubber gaskets or o rings on this injector and anytime you get a polar injector and Replace injector it's definitely a good idea to replace all the rubber components on that injector it's really simple and easy maintenance thing to do when you have these injectors out and I highly recommend it that's what I have right here this is actually a little injector seal kit and it comes with all the little replacement o-rings you need and a little packet of lubricant [Music] here's a close-up of that loo look at that game it's called super lube and you basically want to apply a thin coat of this on these o-rings when you install them on your fuel injectors so I'll go ahead and grab the first injector take this bottom one off get rid of that one this sucker is really hard and really brittle I'm sure you guys probably hear that see how hard that is that's how brittle o-ring is that sucker is really brittle I'll go ahead grab one these new ones look how easy I can squeeze this sucker you can see how easy I can squeeze it that kind of shows a degree of elasticity house okay so that's enough about messing around with that a little bit this lubricant on it just probably have some nitrile gloves on make sure this sucker is clean it's pretty clean I'll go ahead and slide that on the fuel injector we're still gonna replace this seal in this little tiny oring seal all right to remove these seals just go ahead and slide them off they should come off it might be a little bit sticky but they should come right off that's I first see how that suckers off and this one just kind of get a thumbnail in there and peel that sucker off sometimes are a little bit of thing all right and there's that little sucker so go and replace this sucker to make sure you loop this sucker out and then go ahead and slide out without fuel injector all the way on I think it's got a little tube on them right now so I can just kind of leave it up like that I'm go ahead and slide that little o-ring on the top okay there we go this fuel injector is good to go it's got all new seals and it's ready to be installed okay guys and then walk you through installing these fuel injectors on the right side fuel Rahal make it easier for you guys I'm actually gonna flip this intake manifold over but if you're gonna change your fuel injectors in your car you definitely can do it with the intake manifold right side up this way with the intake manifold upside down I think you guys can actually get a better view of how you slide these injectors into these fuel rails we're going to slide this side with a small little o-ring into this little hole in your fuel injector rail and then this side with that large donut oring that's the side that we're going to slide into that hole in your TV's okay so basically we want to do is you want to just kind of twist it back so you can get in there and then slide that sucker rotate it out and it's kind of line it up with the hole and we'll do the same thing for this next one just kind of get it totally perpendicular try to make sure you slide this in perpendicular and just slide it into the hole shouldn't take a whole lot of effort okay I'm gonna flip it over I'll go ahead and bolt these suckers down okay in the factory spec for torquing these bolts down is actually 13.7 foot-pounds so go ahead and grab your torque wrench and torque these bolts down that are holding a fuel rail to your tumble generator valves 13.7 foot-pounds okay at this point you can go ahead and tighten up all your bolts tighten everything down at this point and then you want to go ahead and take that wiring harness and weave it around and start installing it at a bunch of your locations where you can actually connect it to your sensors and that includes these sensors right here these are part your tumble generator valves this one right here and this one right here and then of course you can connect your fuel injector sensors as well right here and right here in addition to those sensors and fuel injectors can also go ahead and connect any ground terminals this term right here actually gets bolted down to the intake manifold right here these two plugs are actually going to plug into your coal packs which sit on top your valve covers so don't worry about connecting these yet well connect these after this whole intake manifold assembly is installed on the engine and the same goes for these don't worry about coming from these at this time we'll connect these once intake manifold is installed back in the engine all right guys we're done with step number five so I'm gonna bust out my dry erase marker and I go ahead and put it checked by number five and we're gonna go ahead and move on to step number six which is installing all the evaporative lines and that little purge solenoid okay so here's all the components for your evap system you actually have your purge solenoid and you have a one-way check valve and I'm gonna walk you guys through how to install these suckers right now it may seem like a whole bunch of hoses once you've seen it installed it's actually pretty straightforward we're gonna start with this sucker right here this is our purge solenoid it actually has a little sensor that plugs into your ECU when you go to install this sucker you can actually use this little cutoff section right here or asymmetrical little wedge section that's cut off and that's the side it actually lines up with a little slot where you bolted in which is actually right here on the bottom of the intake manifold so go ahead and get that sucker lined up and has some that bolt down once it's installed it should be at this like 45-degree cocked angle okay in this first hose is stepping down to that quarter inch hose size that one's gonna go down along the bottom and then turn up right here to connect to that tee fitting that's going into that fuel vapor line right here in this other hose this hose actually connects right here to this port on your intake manifold you go ahead and checked it like that okay then you wanna take that other piece it has that one-way check valve in that three-way little key which as you can see on mine is actually broken the little quarter-inch port on my little three-way key fitting actually broke off so I've actually ordered a new one of these suckers and it's pretty common because these plastic parts and these rubber hoses actually see a lot of heat cycling that actually causes them to get hard and get brittle over time so it's pretty common to have to replace all these parts when you order a new one of these little 3-way T fittings it actually comes with all the little molded hoses as well so I'm going to go ahead and replace all these little molded hoses and that three-way key fitting but for right now I'm going to walk you guys through installing it and then we're gonna go ahead and install this intake manifold on the engine one of the things you can actually look for on this little one-way check valve is just a little arrow on the top this says two and an e / G that arrow should actually be pointing it to your air intake system old hose is actually going to connect to one of those ports on that factory air intake and if we rotate it there's actually a little quarter inch fitting on the backside that quarter inch fitting actually connects right here your intake manifold and then this side this little blue fitting that should be a three-way fitting but it actually has a little nipple broken off this little three-way fitting actually goes down here on the bottom so connect that blue T fitting into that fuel vapor recovery hose and then connect this smaller quarter-inch to little size hose to that smaller low port on this t fitting just like this and that smaller port should rotate down so this hose connect right into that smaller port on the bottom and you can go ahead and connect this a little small quarter inch port right here and this port connects right here to your air intake like that okay and that EVAP system is completely installed and this intake manifold is actually ready to be installed back on this ej 205 engine all right with an installation of those evap lines and that purge solenoid within go ahead knock step 6 off that list so this intake manifold assembly is completely reassembled during go ahead install this sucker back on the engine okay guys anytime we gonna reinstall an intake manifold back on your engine you're gonna want to use new gaskets and these are the gaskets for this 2005 WRX there's a Subaru part number right there I'm using OEM gaskets but really it doesn't matter too much you can use any kind of gas you find it local parts store and then these are all eight of the original bolts and as you can see a lot of these bolts are actually pretty corroded on the threads right here at the tip they got a little bit of white corrosion and you definitely wanna clean that up with a brass wire brush and on this side on the head they don't actually look too great I'll show you right now on the other ones already cleaned up a little bit the one you're looking at on the left I actually just hit up with a wire brush for three or four minutes I'll kind of rotate to the side so you can see the side profiles - so it looks like we hit up with a wire brush just kind of knock off all the oxidation and clean up that surface so I'll go ahead and clean up the rest of these bolts and then we'll use them to install this intake manifold okay all eight of these bolts are totally cleaned up with that brass wire brush I'll go ahead and grab one my new intake manifold gaskets drop it on the engine and install this intake manifold okay guys so we're finally ready to go we've got the intake manifold completely assembled we've got the new gaskets dropped on the engine and a clean up the threads on the old bolts that way we torque these bolts down they'll actually be torque to the correct factory settings which is around eighteen point one foot-pounds now the trick here is actually kind of Bend this hose so it's straight up and vertical and while you bend it you kind of slip this intake manifold up and over that will hose in that guise say get this intake manifold to drop onto this engine you actually have to bend this hose so it's up vertical slightly and then you can weave this hose through these two runners of your intake manifold while you drop it down on to those gaskets and then get it lined up with those bolt holes and then drop those bolts in and torque them down to 18 point 1 foot-pounds okay guys we're on the left side of the engine and there's actually four bolt holes that hold the intake manifold down this side there's one right here there's one right here there's one right here and there's one back here so go ahead and drop those bolts in and lightly Snug them down before I torque them down to that 18.1 foot-pounds okay it's the same key on the right side we have four bolt hole locations one here one here one here and then one right here and when you torque these suckers down you're going to want to start from the inside and work your way out that's a good general rule of thumb anytime you get a torque down to machine services together all right that's 18 point one fifteen point one eight point one all right then you can also start connecting all these miscellaneous hoses and sensors this is part of the PVC system we can connect that sucker now like that and we can come over here to the front we can connect our oil pressure sensor that's this little plug and that just has a little single blade connection and in this plug right here this text to this sensor right here and that's your coolant temperature sensor so go ahead and plug that guy in to push them all the way in toy snaps you know you've got it fully seated okay in this sensor right here outside a little purge solenoid that we installed earlier so reconnect that guy and then this one this actually connects to your crankshaft position sensor now it's the sensor right down here or below so connect that guy as well and make sure it's fully seated lock in place so we have our crankshaft position sensor we have a coolant temperature sensor and we have our oil pressure sensor and then we can move over here and this is our camshaft position sensor we can actually connect the terminal to that guy as well and that's this terminal right here so go ahead and connect that sensor boom done these big plugs these are our main harness plugs that connect once the engines drop back into the vehicle so don't worry about these plugs at this time these plugs actually go to our coil packs and those I don't have installed yet but you definitely wanna install those before you drop this engine back in your car and just like that this intake manifold is back on this engine and this engine is really starting to come along and starting to look like a fully assembled engine I'm stoked guys this thing's getting really close to being dropped back into my 1998 or STI coupe and I hope you guys will join me for those future videos I'm gonna wrap it up here for today guys thank you so much for check out the video I really appreciate it getting questions or any comments please leave them in the comment section below if you like the video please go ahead and give it a like and if you think this video be good for your friends in a super community please go ahead and click and share it with them thanks again for check out the video guys I really appreciate it thanks for joining me my little super early shop here in Northern California my name's Luke this is a super only channel until next time guys later [Music] [Applause] thanks again for watching this video guys as you guys know I'm a die-hard Subaru enthusiast and I've also had the opportunity to be involved in motor sports for over two decades now but I'm also a professional hydrogeologist and have actually spent years in laboratories performing experiments where I studied the flow of fluids using the properties of physics and fluid mechanics in these youtube videos I'm actually able to combine my experience from the laboratories and all the research I've done with my experience from although motorsport series I've been involved in and my passion for Subarus if you have any professional inquiries about subaru related R&D or digital marketing in media you can contact me at Subaru only shop at gmail.com or if you work in private industry or for a public municipality and you'd like to contact me for professional environmental or engineering and design services you can review my professional academic background mike professional research experience and my professional consulting experience on linkedin just go ahead and science linkedin and look for luke shannon and then type TRC that's the company I currently work for if you type Luke Shannon and TR see I'm the only person that's gonna come up thanks for checking out the video guys I really appreciate it I hope to hear from you soon

Channel: SubaruONLY

Views: 77,599

Keywords: subaruonly, subaruonlyshow, subaru only, only subaru, subaru diy, subaru intake manifold, wrx intake manifold, sti intake manifold, sti red intake manifold, rsti, r-sti, subaru wrx intake manifold, how to install wrx intake manifold, install intake manifold, install wrx intake, install sti intake, install wrx sti intake manifold, subaru vlog, subaru 22b, 1998 subaru rs, subaru rs, subaru swap, subaru impreza rs, subaru sti swap, subaru tgv

Id: SFKJ72Ig-mE

Length: 28min 10sec (1690 seconds)

Published: Sun Oct 06 2019