Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSSUBARU2004OUTBACK BASE, 4D WAGON, EJ251, STANDARDREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCEENGINE CONTROL SYSTEMSFUEL INJECTION (FUEL SYSTEMS) (H4SO)INTAKE MANIFOLDDISASSEMBLY

2004 Subaru Outback Base, 4D Wagon, EJ251, Standard

Intake Manifold: Disassembly

2004 Subaru Outback Base, 4D Wagon, EJ251, StandardSECTION Disassembly

Disconnect engine ground terminal from intake manifold.

Fig 1: Disconnecting Engine Ground Terminal From Intake Manifold
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Disconnect connector from ignition coil and ignitor assembly.

Fig 2: Disconnecting Connector From Ignition Coil & Ignitor Assembly
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Remove ignition coil and ignitor assembly.

Fig 3: Removing Ignition Coil & Ignitor Assembly
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Remove throttle body. Refer to REMOVAL , Throttle Body.
Remove air assist injector solenoid valve. Refer to REMOVAL , Air Assist Injector Solenoid Valve.
Remove EGR valve. Refer to REMOVAL , EGR Valve.
Disconnect pressure regulator vacuum hose from intake manifold.

Fig 4: Disconnecting Pressure Regulator Vacuum Hose From Intake Manifold
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Remove fuel pipe protector LH.

Fig 5: Removing Fuel Pipe Protector LH
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Remove fuel pipe protector RH.

Fig 6: Removing Fuel Pipe Protector RH
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Disconnect connectors from fuel injectors.

Fig 7: Disconnecting Connectors From Fuel Injectors
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Disconnect connector from purge control solenoid valve.

Fig 8: Disconnecting Connector From Purge Control Solenoid Valve
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Disconnect air by-pass hose from purge control solenoid valve.
Remove harness bands (A) which hold engine harness onto intake manifold.

Fig 9: Removing Harness Bands
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Remove engine harness from intake manifold.
Remove purge control solenoid valve.

Fig 10: Removing Purge Control Solenoid Valve
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Remove bolt which installs injector pipe on intake manifold as shown in figure.

Fig 11: Removing Bolt Which Installs Injector Pipe On Intake Manifold
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Remove two bolts which hold fuel pipes on the left side of intake manifold.

Fig 12: Removing Two Bolts Which Hold Fuel Pipes On Left Side Of Intake Manifold
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Remove fuel injectors.
1. Remove fuel injector securing clip.
  
  Fig 13: Removing Fuel Injector Securing Clip
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2. Remove fuel injector while lifting up fuel injector pipe.
Fig 14: Removing Fuel Injector
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Disconnect air by-pass hoses from intake manifold.

Fig 15: Disconnecting Air By-Pass Hoses From Intake Manifold
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Loosen clamp which holds front left side fuel hose to injector pipe and remove the pipe from clamp.

Fig 16: Removing Pipe From Clamp
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Loosen clamp which holds front right side fuel hose to injector pipe and remove the pipe from clamp.

Fig 17: Removing Pipe From Clamp
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Remove fuel injector pipe.
Remove bolt which installs fuel pipes on intake manifold.

Fig 18: Removing Bolt Which Installs Fuel Pipes On Intake Manifold
Courtesy of SUBARU OF AMERICA, INC.
Remove fuel pipe assembly and pressure regulator, from intake manifold.