2004 Subaru Outback Base, 4D SedanFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Assembly

  1. Install intake induction valve vacuum hose to intake manifold.
    Fig 1: Installing Intake Induction Valve Vacuum Hose
    G00897206Courtesy of SUBARU OF AMERICA, INC.
  2. Install fuel pipe and injector pipe assembly.

    Tightening torque: 

    1. 5.0 N.m (0.51 kgf-m, 3.7 ft-lb) 
    Fig 2: Installing Fuel Pipe And Injector Pipe Assembly
    G00897207Courtesy of SUBARU OF AMERICA, INC.
  3. Connect pressure regulator vacuum hose (A) to intake manifold.
    Fig 3: Connecting Pressure Regulator Vacuum Hose
    G00897208Courtesy of SUBARU OF AMERICA, INC.
  4. Install air assist and purge pipe assembly.

    Tightening torque: 

    1. 5.0 N.m (0.51 kgf-m, 3.7 ft-lb) 
    Fig 4: Installing Air Assist And Purge Pipe Assembly
    G00897209Courtesy of SUBARU OF AMERICA, INC.
  5. Install PCV pipe to intake manifold.

    Tightening torque: 

    1. 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 
    Fig 5: Installing PCV Pipe
    G00897210Courtesy of SUBARU OF AMERICA, INC.
  6. Install engine harness assembly to intake manifold.

    Tightening torque: 

    1. 5.0 N.m (0.51 kgf-m, 3.7 ft-lb) 
    Fig 6: Installing Engine Harness Assembly
    G00897211Courtesy of SUBARU OF AMERICA, INC.
  7. Install EGR valve.

    Tightening torque: 

    1. 19 N.m (1.9 kgf-m, 14 ft-lb) 
    NOTE: When removing EGR valve, use a new gasket.
  8. Connect connector to EGR valve.
    Fig 7: Connecting EGR Valve Connector
    G00897212Courtesy of SUBARU OF AMERICA, INC.
  9. Install purge control solenoid valve.

    Tightening torque: 

    1. 19 N.m (1.9 kgf-m, 14 ft-lb) 
  10. Connect connector to purge control solenoid valve.
    Fig 8: Connecting Purge Control Solenoid Valve Connector
    G00897213Courtesy of SUBARU OF AMERICA, INC.
  11. Connect hoses to purge control solenoid valve.
    CAUTION: Carefully connect the evaporation hoses.
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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