2005 Subaru Outback RFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Installation

  1. Install the intake manifold onto cylinder heads.
    NOTE: Use a new O-ring.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18 ft-lb) 

    • RH side
      Fig 1: Installing Intake Manifold Bolts (RH)
      G03830205Courtesy of SUBARU OF AMERICA, INC.
    • LH side
    Fig 2: Installing Intake Manifold Bolts (LH)
    G03830206Courtesy of SUBARU OF AMERICA, INC.
  2. Install the bolts, which hold fuel injector pipe RH onto cylinder head.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14 ft-lb) 

    Fig 3: Installing Fuel Injector Pipe RH Bolt
    G03830207Courtesy of SUBARU OF AMERICA, INC.
  3. Install the engine harness to fuel injector pipe RH.
  4. Install the fuel pipe protector RH.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14 ft-lb) 

    Fig 4: Installing Fuel Pipe Protector RH
    G03830208Courtesy of SUBARU OF AMERICA, INC.
  5. Install the bolts which hold fuel injector pipe LH onto cylinder head.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14 ft-lb) 

    Fig 5: Installing Fuel Injector Pipe LH Bolts
    G03830209Courtesy of SUBARU OF AMERICA, INC.
  6. Install the engine harness to fuel injector pipe LH.
  7. Install the fuel pipe protector LH.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14 ft-lb) 

    Fig 6: Installing Fuel Pipe Protector LH
    G03830210Courtesy of SUBARU OF AMERICA, INC.
  8. Connect the fuel hoses to fuel pipe.
    Fig 7: Connecting Fuel Hoses To Fuel Pipe
    G03830211Courtesy of SUBARU OF AMERICA, INC.
  9. Connect the brake booster hose.
    Fig 8: Connecting Brake Booster Hose
    G03830212Courtesy of SUBARU OF AMERICA, INC.
  10. Connect the PCV hose.
    Fig 9: Connecting PCV Hose
    G03830213Courtesy of SUBARU OF AMERICA, INC.
  11. Connect the engine coolant hoses to throttle body.
    Fig 10: Connecting Engine Coolant Hoses To Throttle Body
    G03830214Courtesy of SUBARU OF AMERICA, INC.
  12. Connect the connector to throttle body.
    Fig 11: Connecting Connector To Throttle Body
    G03830215Courtesy of SUBARU OF AMERICA, INC.
  13. Install the generator. < Ref. to INSTALLATION , Generator. >
  14. Install the air cleaner case and air intake chamber. < Ref. to INSTALLATION , Air Cleaner Case.> < Ref. to INSTALLATION , Air Intake Chamber. >
  15. Install the fuse of fuel pump to main fuse box.
  16. Connect the battery ground cable to battery.
    Fig 12: Connecting Battery Ground Cable To Battery
    G03830216Courtesy of SUBARU OF AMERICA, INC.
  17. Install the collector cover.
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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