2002 Subaru Outback Base, 4D SedanFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Disassembly

  1. Disconnect connectors from throttle position sensor.
    Fig 1: Disconnecting Connectors From Throttle Position Sensor
    G03584176Courtesy of SUBARU OF AMERICA, INC.
  2. Disconnect connectors from intake manifold pressure sensor (B) and idle air control solenoid valve (A).
  3. Disconnect air by-pass hose (C) from idle air control solenoid valve.
    Fig 2: Disconnecting Air By-Pass Hose (C) From Idle Air Control Solenoid Valve
    G03584177Courtesy of SUBARU OF AMERICA, INC.
  4. Remove throttle body.
    Fig 3: Removing Throttle Body
    G03584178Courtesy of SUBARU OF AMERICA, INC.
  5. Remove induction valve.
    Fig 4: Removing Induction Valve
    G03584179Courtesy of SUBARU OF AMERICA, INC.
  6. Disconnect connector from induction valve control solenoid.
  7. Remove induction valve control solenoid.
    Fig 5: Removing Induction Valve Control Solenoid
    G03584180Courtesy of SUBARU OF AMERICA, INC.
  8. Disconnect connector from purge control solenoid valve.
  9. Remove purge control solenoid valve.
    Fig 6: Removing Purge Control Solenoid Valve
    G03584181Courtesy of SUBARU OF AMERICA, INC.
  10. Disconnect connector from EGR valve.
  11. Remove EGR valve.
    Fig 7: Removing EGR Valve
    G03584182Courtesy of SUBARU OF AMERICA, INC.
  12. Remove engine harness assembly from intake manifold.
    Fig 8: Removing Engine Harness Assembly From Intake Manifold
    G03584183Courtesy of SUBARU OF AMERICA, INC.
  13. Remove PCV pipe from intake manifold.
    Fig 9: Removing PCV Pipe From Intake Manifold
    G03584184Courtesy of SUBARU OF AMERICA, INC.
  14. Remove air assist and purge pipe assembly.
    Fig 10: Removing Air Assist And Purge Pipe Assembly
    G03584185Courtesy of SUBARU OF AMERICA, INC.
  15. Disconnect pressure regulator vacuum hose (A) from intake manifold.
  16. Remove fuel pipe and injector pipe assembly.
    Fig 11: Removing Fuel Pipe And Injector Pipe Assembly (1 Of 2)
    G03584186Courtesy of SUBARU OF AMERICA, INC.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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