2005 Subaru Outback i, StandardFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Removal

  1. Release the fuel pressure. < Ref. to , RELEASING OF FUEL PRESSURE , PROCEDURE, Fuel. >
  2. Open the fuel filler flap lid, and remove the fuel filler cap.
  3. Disconnect the ground cable from battery.
    Fig 1: Disconnecting Ground Cable From Battery
    G03827634Courtesy of SUBARU OF AMERICA, INC.
  4. Remove the air cleaner case and air intake chamber. < Ref. to REMOVAL , Air Cleaner Case.> < Ref. to REMOVAL , Air Intake Chamber. >
  5. Remove the generator. < Ref. to REMOVAL , Generators. >
  6. Disconnect the spark plug cords from spark plugs by pulling the plug cap. (Do not pull the cord.)
  7. Disconnect the engine coolant hoses (A) from throttle body.
    Fig 2: Disconnecting Engine Coolant Hoses (A) From Throttle Body
    G03827635Courtesy of SUBARU OF AMERICA, INC.
  8. Disconnect the brake booster hose (A).
    Fig 3: Disconnecting Brake Booster Hose (A)
    G03827636Courtesy of SUBARU OF AMERICA, INC.
  9. Disconnect the PCV hoses (A) from intake manifold.
  10. Disconnect the engine harness connectors (B) from bulkhead harness connectors.
    Fig 4: Disconnecting Engine Harness Connectors (B) From Bulkhead Harness Connectors
    G03827637Courtesy of SUBARU OF AMERICA, INC.
  11. Disconnect the connectors from engine coolant temperature sensor.
    Fig 5: Disconnecting Connectors From Engine Coolant Temperature Sensor
    G03827638Courtesy of SUBARU OF AMERICA, INC.
  12. Disconnect the knock sensor connector.
    Fig 6: Disconnecting Knock Sensor Connector
    G03827639Courtesy of SUBARU OF AMERICA, INC.
  13. Disconnect the connector from crankshaft position sensor.
    Fig 7: Disconnecting Connector From Crankshaft Position Sensor
    G03827640Courtesy of SUBARU OF AMERICA, INC.
  14. Disconnect the connector from power steering pump switch (A).
  15. Disconnect the connector from oil pressure switch (B).
    Fig 8: Disconnecting Connector From Oil Pressure Switch (B)
    G03827641Courtesy of SUBARU OF AMERICA, INC.
  16. Disconnect the connector from camshaft position sensor.
    Fig 9: Disconnecting Connector From Camshaft Position Sensor
    G03827642Courtesy of SUBARU OF AMERICA, INC.
  17. Remove the EGR pipe from intake manifold.
    Fig 10: Removing EGR Pipe From Intake Manifold
    G03827643Courtesy of SUBARU OF AMERICA, INC.
  18. Disconnect the fuel hoses from fuel pipes.
    1. Push the ST to separate the connectors of fuel delivery line and return line.

      ST 42099AE000 CONNECTOR REMOVER

    2. Remove the clip to disconnect evaporation hoses from pipe.
    WARNING:
    • Be careful not to spill fuel.
    • Catch the fuel from hoses using a container or cloth.
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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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