2005 Subaru Outback i, AutomaticFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Assembly

  1. Install the intake manifold.
    NOTE:
    • Use a new gasket.
    • When assembling the nipple, apply liquid gasket.

    Liquid gasket: 

    THREE BOND 1105 (Part No. 004403010) 

    Tightening torque: 

    8.75 N.m (0.89 kgf-m, 6.5 ft-lb) 

    Fig 1: Installing Intake Manifold
    G03827673Courtesy of SUBARU OF AMERICA, INC.
  2. Tighten the bolt which installs the fuel pipes on intake manifold.

    Tightening torque: 

    6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

    Fig 2: Tightening Bolt Installing Fuel Pipes On Intake Manifold
    G03827674Courtesy of SUBARU OF AMERICA, INC.
  3. Tighten the bolt which installs pressure regulator on intake manifold.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14 ft-lb) 

  4. Connect the fuel injector pipe.
  5. Connect the fuel injector pipe LH to fuel hose, and tighten the clamp screw.
    Fig 3: Connecting Fuel Injector Pipe LH To Fuel Hose
    G03827675Courtesy of SUBARU OF AMERICA, INC.
  6. Connect the fuel injector pipe RH to fuel hose, and tighten the clamp screw.
    Fig 4: Connecting Fuel Injector Pipe RH To Fuel Hose
    G03827676Courtesy of SUBARU OF AMERICA, INC.
  7. Install the fuel injectors.
  8. Tighten the bolts which install injector pipe on intake manifold.
    • RH side

      Tightening torque: 

      19 N.m (1.9 kgf-m, 14 ft-lb) 

      Fig 5: Tightening Bolts Installing Injector Pipe On Intake Manifold - RH Side
      G03827677Courtesy of SUBARU OF AMERICA, INC.
    • LH side

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14 ft-lb) 

    Fig 6: Tightening Bolts Installing Injector Pipe On Intake Manifold - LH Side
    G03827678Courtesy of SUBARU OF AMERICA, INC.
  9. Tighten the two bolts which install fuel pipes on intake manifold.

    Tightening torque: 

    6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

    Fig 7: Tighten Two Bolts Which Install Fuel Pipes On Intake Manifold
    G03827679Courtesy of SUBARU OF AMERICA, INC.
  10. Install the engine harness onto intake manifold.
  11. Tighten the bolts which install engine harness on intake manifold.

    Tightening torque: 

    16 N.m (1.6 kgf-m, 11.8 ft-lb) 

    Fig 8: Tightening Bolts Installing Engine Harness On Intake Manifold
    G03827680Courtesy of SUBARU OF AMERICA, INC.
  12. Hold the engine harness by harness band clips.
    Fig 9: Holding Engine Harness By Harness Band Clips
    G03827681Courtesy of SUBARU OF AMERICA, INC.
  13. Install the purge control solenoid valve. < Ref. to INSTALLATION , Purge Control Solenoid Valve. >
  14. Connect the connectors (A) to fuel injector.
  15. Hold the engine harness to injector pipe by clip (B).
    Fig 10: Holding Engine Harness To Injector Pipe By Clip (B)
    G03827682Courtesy of SUBARU OF AMERICA, INC.
  16. Connect the pressure regulator vacuum hose (A) to intake manifold.
    Fig 11: Connecting Pressure Regulator Vacuum Hose (A) To Intake Manifold
    G03827683Courtesy of SUBARU OF AMERICA, INC.
  17. Install the fuel pipe protector RH.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14 ft-lb) 

    Fig 12: Installing Fuel Pipe Protector RH
    G03827684Courtesy of SUBARU OF AMERICA, INC.
  18. Install the fuel pipe protector LH.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14 ft-lb) 

    Fig 13: Installing Fuel Pipe Protector LH
    G03827685Courtesy of SUBARU OF AMERICA, INC.
  19. Install the PCV pipe.

    Tightening torque: 

    6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

    Fig 14: Installing PCV Pipe
    G03827686Courtesy of SUBARU OF AMERICA, INC.
  20. Install the EGR valve. < Ref. to , INSTALLATION , EGR Valve. >
  21. Install the throttle body to intake manifold. < Ref. to , INSTALLATION , Throttle Body. >
  22. Install the ignition coil & ignitor ASSY. < Ref. to INSTALLATION , Ignition Coil and Ignitor Assembly. >
  23. Install the engine ground terminal to intake manifold.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14 ft-lb) 

    Fig 15: Installing Engine Ground Terminal To Intake Manifold
    G03827687Courtesy 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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