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 MANIFOLDINSTALLATION

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

Intake Manifold: Installation

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

Install intake manifold onto cylinder heads.
NOTE: Always use new gaskets.
1. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
Fig 1: Installing Intake Manifold Onto Cylinder Heads
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Connect fuel hoses.

Fig 2: Connecting Fuel Hoses
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Install EGR pipe to intake manifold and cylinder head.
1. Tightening torque: 33 N.m (3.4 kgf-m, 24.6 ft-lb)
Fig 3: Installing EGR Pipe To Intake Manifold And Cylinder Head
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Connect connector to camshaft position sensor.

Fig 4: Connecting Connector To Camshaft Position Sensor
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Connect connector to oil pressure switch.

Fig 5: Connecting Connector To Oil Pressure Switch
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Connect connector to crankshaft position sensor.

Fig 6: Connecting Connector To Crankshaft Position Sensor
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Connect knock sensor connector.

Fig 7: Connecting Knock Sensor Connector
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Connect connector to engine coolant temperature sensor.

Fig 8: Connecting Connector To Engine Coolant Temperature Sensor
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Install air cleaner case stay RH and engine harness bracket, and connect engine harness connectors to bulkhead connectors.

Fig 9: Installing Air Cleaner Case Stay RH & Engine Harness Bracket
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Connect brake booster hose.

Fig 10: Connecting Brake Booster Hose
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Connect engine coolant hose (A) to throttle body.

Fig 11: Connecting Engine Coolant Hose To Throttle Body
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Connect PCV hose to intake manifold.

Fig 12: Connecting PCV Hose To Intake Manifold
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Connect spark plug cords to spark plugs.
Install power steering pump and tank on brackets.
1. Install power steering tank on bracket.
  
  Fig 13: Installing Power Steering Tank On Bracket
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2. Connect connector to power steering pump switch.
  
  Fig 14: Connecting Connector To Power Steering Pump Switch
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3. Tighten bolts which install power steering pump on bracket.
  1. Tightening torque: 22 N.m (2.2 kgf-m, 15.9 ft-lb)
  Fig 15: Tightening Bolts Which Install Power Steering Pump On Bracket
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4. Install power steering pipes onto right side intake manifold protector.
  
  Fig 16: Installing Power Steering Pipes Onto Right Side Intake Manifold Protector
  Courtesy of SUBARU OF AMERICA, INC.
5. Install front V-belt. Refer to INSTALLATION , V-belt.
6. Install resonator chamber.
1. Tightening torque: 33 N.m (3.4 kgf-m, 24.6 ft-lb)
Fig 17: Installing Resonator Chamber
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Connect accelerator control cable (A).
Connect cruise control cable (B). (With cruise control models)

Fig 18: Connecting Cruise Control Cable
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Install air intake duct and air cleaner case. Refer to INSTALLATION , Air Intake Duct and INSTALLATION , Air Cleaner.
Connect connector to fuel pump relay.

Fig 19: Connecting Connector To Fuel Pump Relay
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Connect battery ground cable.

Fig 20: Connecting Battery Ground Cable
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