2005 Subaru Outback XT, StandardFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Disassembly

  1. Disconnect the engine ground terminal from ground stay.
    Fig 1: Disconnecting Engine Ground Terminal From Ground Stay
    G03829261Courtesy of SUBARU OF AMERICA, INC.
  2. Remove the solenoid valve bracket assembly from intake manifold, and disconnect the connector from the wastegate control solenoid valve, manifold absolute pressure sensor and purge control solenoid valve.
    Fig 2: Disconnecting Connector
    G03829262Courtesy of SUBARU OF AMERICA, INC.
  3. Disconnect the evaporation hoses (A) and filter assembly (B).
    Fig 3: Disconnecting Evaporation Hoses And Filter Assembly
    G03829263Courtesy of SUBARU OF AMERICA, INC.
  4. Disconnect the connector from throttle position sensor.
    Fig 4: Disconnecting Connector From Throttle Position Sensor
    G03829264Courtesy of SUBARU OF AMERICA, INC.
  5. Remove the throttle body from intake manifold.
    Fig 5: Removing Throttle Body From Intake Manifold
    G03829265Courtesy of SUBARU OF AMERICA, INC.
  6. Disconnect the connectors from fuel injector (A), tumble generator valve position sensor (B) and tumble generator valve actuator (C).
    Fig 6: Disconnecting Connectors From Fuel Injector, Tumble Generator Valve Position Sensor And Tumble Generator Valve Actuator
    G03829266Courtesy of SUBARU OF AMERICA, INC.
  7. Remove the bolt which secures the air bypass pipe to intake manifold.
    Fig 7: Removing Bolt
    G03829267Courtesy of SUBARU OF AMERICA, INC.
  8. Disconnect the PCV pipe (A), harness assembly (B) and intake duct (C) from intake manifold.
    Fig 8: Disconnecting PCV Pipe, Harness Assembly And Intake Duct From Intake Manifold
    G03829268Courtesy of SUBARU OF AMERICA, INC.
  9. Remove the bolt which holds fuel injector pipe LH onto the front side of intake manifold.
    Fig 9: Removing Bolt
    G03829269Courtesy of SUBARU OF AMERICA, INC.
  10. Remove the coolant filler tank stay from intake manifold.
    Fig 10: Removing Coolant Filler Tank Stay From Intake Manifold
    G03829270Courtesy of SUBARU OF AMERICA, INC.
  11. Remove the bolts which hold fuel injector pipe onto intake manifold.
    • RH side
      Fig 11: Removing Bolts Which Hold Fuel Injector Pipe Onto Intake Manifold - RH Side
      G03829271Courtesy of SUBARU OF AMERICA, INC.
    • LH side
      Fig 12: Removing Bolts Which Hold Fuel Injector Pipe Onto Intake Manifold - LH Side
      G03829272Courtesy of SUBARU OF AMERICA, INC.
  12. Remove the bolt which holds the fuel pipe to intake manifold.
    Fig 13: Removing Bolt Which Holds Fuel Pipe To Intake Manifold
    G03829273Courtesy of SUBARU OF AMERICA, INC.
  13. Remove the bolts which hold the fuel injector pipe RH onto the lower side of intake manifold.
    Fig 14: Removing Bolts
    G03829274Courtesy of SUBARU OF AMERICA, INC.
  14. Loosen the clamp which holds fuel hose to injector pipe, and then disconnect the pipe from fuel hose.
    Fig 15: Loosening Clamp
    G03829275Courtesy of SUBARU OF AMERICA, INC.
  15. Remove the fuel injector pipe.
  16. Remove the intake manifold (upper) from intake manifold (lower).
Fig 16: Removing Intake Manifold (Upper) From Intake Manifold (Lower)
G03829276Courtesy 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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