2006 Subaru Outback XT Limited, AutomaticFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Assembly

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

    Tightening torque: 

    8.3 N.m (0.85 kgf-m, 6.1 ft-lb) 

    Fig 1: Identifying Intake Manifolds
    G05017777
  2. Install the fuel injector pipe.
  3. Connect fuel hoses to fuel injector pipes on both sides, and secure them with the clamps.
    Fig 2: Identifying Fuel Injector Pipe Hose Clamp
    G05017776
  4. Tighten the bolts which secure the fuel injector pipe RH to the lower side of the intake manifold.

    Tightening torque: 

    6.5 N.m (0.66 kgf-m, 4.8 ft-lb) 

    Fig 3: Locating Fuel Injector Pipe RH Onto Lower Side Of Intake Manifold Bolts
    G05017775
  5. Tighten the bolts which secure the fuel pipe to the intake manifold.

    Tightening torque: 

    6.5 N.m (0.66 kgf-m, 4.8 ft-lb) 

    Fig 4: Locating Fuel Pipe Bolts
    G05017774
  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: Locating Fuel Injector Pipe Onto Intake Manifold Bolts - LH Side
      G05017773
    • RH side
      Fig 6: Locating Fuel Injector Pipe Onto Intake Manifold Bolts - RH Side
      G05017772
  7. Install the coolant filler tank stay to the intake manifold.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14 ft-lb) 

    Fig 7: Identifying Coolant Filler Tank Stay From Intake Manifold
    G05017771
  8. Tighten the bolt which holds the fuel injector pipe LH to the front side of the intake manifold.

    Tightening torque: 

    6.5 N.m (0.66 kgf-m, 4.8 ft-lb) 

    Fig 8: Locating Fuel Injector Pipe Bolt
    G05017770
  9. Install PCV pipe (A), harness assembly (B) and intake duct (C) to the intake manifold.

    Tightening torque: 

    6.5 N.m (0.66 kgf-m, 4.8 ft-lb) 

    Fig 9: Identifying PCV Pipe, Harness Assembly And Intake Duct From Intake Manifold
    G05017769
  10. Tighten the bolts which secure the air bypass pipe to the intake manifold.

    Tightening torque: 

    6.5 N.m (0.66 kgf-m, 4.8 ft-lb) 

    Fig 10: Locating Air By-Pass Pipe Bolts
    G05017768
  11. Install the connectors to fuel injector (A), tumble generator valve position sensor (B) and tumble generator valve actuator (C).
    Fig 11: Identifying Fuel Injector, Tumble Generator Valve Position Sensor And Tumble Generator Valve Actuator
    G05017767
  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: Locating Throttle Body To Intake Manifold Bolts
    G05017734
  13. Connect the connector to the throttle position sensor.
    Fig 13: Locating Throttle Position Sensor Connector
    G05017732
  14. Connect the evaporation hose (A) and filter assembly (B).
    Fig 14: Identifying Evaporation Hose And Filter Assembly
    G05017764
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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.