2005 Subaru Outback XT, AutomaticFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Assembly

  1. Install the intake manifold (lower) to intake manifold (upper).
    NOTE: Use new O-rings.

    Tightening torque: 

    8.3 N.m (0.85 kgf-m, 6.1 ft-lb) 

    Fig 1: Installing Intake Manifold (Lower) To Intake Manifold (Upper)
    G03829277Courtesy of SUBARU OF AMERICA, INC.
  2. Install the fuel injector pipe.
  3. Connect the both fuel injector pipes with a fuel hose and secure them with clamps.
    Fig 2: Connecting Both Fuel Injector Pipes With Fuel Hose
    G03829278Courtesy of SUBARU OF AMERICA, INC.
  4. Tighten the bolt which secures the fuel injector pipe RH onto the lower side of intake manifold.

    Tightening torque: 

    6.5 N.m (0.66 kgf-m, 4.8 ft-lb) 

    Fig 3: Tightening Bolt
    G03829279Courtesy of SUBARU OF AMERICA, INC.
  5. Tighten the bolt which secures fuel pipe onto intake manifold.

    Tightening torque: 

    6.5 N.m (0.66 kgf-m, 4.8 ft-lb) 

    Fig 4: Tightening Bolt
    G03829280Courtesy of SUBARU OF AMERICA, INC.
  6. Tighten the bolts which secure fuel injector pipe onto intake manifold.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14 ft-lb) 

    • LH side
      Fig 5: Tightening Bolt - LH Side
      G03829281Courtesy of SUBARU OF AMERICA, INC.
    • RH side
      Fig 6: Tightening Bolt - RH Side
      G03829282Courtesy of SUBARU OF AMERICA, INC.
  7. Install the coolant filler tank stay to intake manifold.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14 ft-lb) 

    Fig 7: Installing Coolant Filler Tank Stay To Intake Manifold
    G03829283Courtesy of SUBARU OF AMERICA, INC.
  8. Tighten the bolt which installs fuel injector pipe LH on the front side of intake manifold.

    Tightening torque: 

    6.5 N.m (0.66 kgf-m, 4.8 ft-lb) 

    Fig 8: Tightening Bolt
    G03829284Courtesy of SUBARU OF AMERICA, INC.
  9. Install the PCV pipe (A), harness assembly (B) and intake duct (C) to intake manifold.

    Tightening torque: 

    6.5 N.m (0.66 kgf-m, 4.8 ft-lb) 

    Fig 9: Installing PCV Pipe, Harness Assembly And Intake Duct To Intake Manifold
    G03829285Courtesy of SUBARU OF AMERICA, INC.
  10. Tighten the bolt which secures air bypass pipe onto intake manifold.

    Tightening torque: 

    6.5 N.m (0.66 kgf-m, 4.8 ft-lb) 

    Fig 10: Tightening Bolt Securing Air Bypass Pipe Onto Intake Manifold
    G03829286Courtesy of SUBARU OF AMERICA, INC.
  11. Install the connectors to fuel injector (A), tumble generator valve position sensor (B) and tumble generator valve actuator (C).
    Fig 11: Installing Connectors To Fuel Injector, Tumble Generator Valve Position Sensor And Tumble Generator Valve Actuator
    G03829287Courtesy of SUBARU OF AMERICA, INC.
  12. Install the throttle body to intake manifold.
    NOTE: Use new O-rings.

    Tightening torque: 

    8 N.m (0.8 kgf-m, 5.9 ft-lb) 

    Fig 12: Installing Throttle Body To Intake Manifold
    G03829288Courtesy of SUBARU OF AMERICA, INC.
  13. Connect the connector to throttle position sensor.
    Fig 13: Connecting Connector To Throttle Position Sensor
    G03829289Courtesy of SUBARU OF AMERICA, INC.
  14. Connect the evaporation hoses (A) and filter assembly (B).
    Fig 14: Connecting Evaporation Hoses And Filter Assembly
    G03829290Courtesy 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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