Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSSUBARU2005OUTBACK I, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 44 (HVAC SYSTEM (HEATER, VENTILATOR AND A/C))INTAKE UNITREMOVAL

2005 Subaru Outback i, Standard

Intake Unit: Removal

2005 Subaru Outback i, StandardSECTION Removal

WARNING: This page is about a different car, the 2005 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.

Using refrigerant recovery system, discharge refrigerant. < Ref. to , OPERATION , Refrigerant Recovery Procedure. >
Disconnect ground cable from battery.
Remove bolts securing expansion valve and pipe in engine compartment.

Fig 1: Removing Bolts Securing Expansion Valve And Pipe In Engine Compartment
Courtesy of SUBARU OF AMERICA, INC.
Remove instrument panel. < Ref. to REMOVAL , Instrument Panel Assembly .>
Remove keyless unit and cruise unit.

Fig 2: Removing Keyless Unit And Cruise Unit
Courtesy of SUBARU OF AMERICA, INC.
Disconnect sunroof connector.
Disconnect servo motor connector.

Fig 3: Disconnecting Servo Motor Connector
Courtesy of SUBARU OF AMERICA, INC.
Disconnect blower power transistor connector.
Disconnect blower motor connector.
Disconnect evaporator sensor connector.

Fig 4: Disconnecting Evaporator Sensor Connector
Courtesy of SUBARU OF AMERICA, INC.
Remove bolts and nuts on the intake unit.

Fig 5: Removing Bolts And Nuts On Intake Unit
Courtesy of SUBARU OF AMERICA, INC.
Disconnect drain hose.
Remove the intake unit.

RENDER: 1.0x

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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.