2008 Subaru Outback Base, AutomaticFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Installation

  1. Install the intake manifold onto cylinder heads.
    NOTE: Use a new gasket.

    Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb) 

    Fig 1: Locating Intake Manifold Bolts
    G04997342Courtesy of SUBARU OF AMERICA, INC.
  2. Connect the fuel hose and evaporation hose to the fuel pipe.
    NOTE: If fuel hoses or clamps are damaged, replace them with new parts.

    Tightening torque: 1.25 N.m (0.13 kgf-m, 0.94 ft-lb) 

  3. Install the EGR pipe to intake manifold.

    Tightening torque: 34 N.m (3.4 kgf-m, 24.6 ft-lb) 

    Fig 2: Identifying EGR Pipe From Intake Manifold
    G05332711Courtesy of SUBARU OF AMERICA, INC.
  4. Connect the following connectors.
    1. Front oxygen (A/F) sensor connector
    2. Rear oxygen sensor connector
    3. Engine harness connectors
  5. Connect the connectors to camshaft position sensor.
    Fig 3: Identifying Camshaft Position Sensor
    G04997339Courtesy of SUBARU OF AMERICA, INC.
  6. Connect the connector to the power steering pump switch (A).
  7. Connect the connector to the oil pressure switch (B).
    Fig 4: Identifying Power Steering Pump Switch And Oil Pressure Switch
    G05016750Courtesy of SUBARU OF AMERICA, INC.
  8. Connect the connector to crankshaft position sensor.
    Fig 5: Identifying Crankshaft Position Sensor
    G04997337Courtesy of SUBARU OF AMERICA, INC.
  9. Connect the knock sensor connector.
    Fig 6: Identifying Knock Sensor Connector
    G04997336Courtesy of SUBARU OF AMERICA, INC.
  10. Connect the connector to engine coolant temperature sensor.
    Fig 7: Identifying Engine Coolant Temperature Sensor
    G04997335Courtesy of SUBARU OF AMERICA, INC.
  11. Connect the PCV hose (A) to intake manifold.
  12. Connect the engine harness connectors (B) to bulkhead harness connectors.
    Fig 8: Identifying PCV Hose And Engine Harness Connector
    G04997334Courtesy of SUBARU OF AMERICA, INC.
  13. Connect the brake booster hose (A).
    Fig 9: Identifying Brake Booster Hose
    G04997333Courtesy of SUBARU OF AMERICA, INC.
  14. Connect the engine coolant hoses (A) to throttle body.
    Fig 10: Identifying Engine Coolant Hoses
    G04997332Courtesy of SUBARU OF AMERICA, INC.
  15. Connect the spark plug cords to spark plugs.
  16. Install the generator. <Ref. to INSTALLATION , Generators .>
  17. Install the air intake duct, air cleaner case and air intake chamber. <Ref. to INSTALLATION , Air Intake Duct .> <Ref. to INSTALLATION , Air Cleaner Case .> <Ref. to INSTALLATION , Air Intake Chambers .>
  18. Install the fuse of fuel pump relay to the main fuse box.
  19. Connect the battery ground cable to battery.
    Fig 11: Identifying Ground Cable From Battery
    G05019586Courtesy 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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