2008 Subaru Outback Limited, AutomaticFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Removal

  1. Release the fuel pressure.

    <Ref. to RELEASING OF FUEL PRESSURE , PROCEDURE, Fuel .>

  2. Disconnect the ground cable from the battery.
    Fig 1: Identifying Ground Cable From Battery
    G05019586Courtesy of SUBARU OF AMERICA, INC.
  3. Open the fuel filler flap lid, and remove the fuel filler cap.
  4. Remove the air intake duct, air cleaner case and air intake chamber. <Ref. to REMOVAL , Air Intake Duct .> <Ref. to REMOVAL , Air Cleaner Case .> <Ref. to REMOVAL , Air Intake Chamber .>
  5. Remove the generator. <Ref. to REMOVAL , Generators .>
  6. Remove the spark plug cords from the spark plugs by pulling the plug caps. (Do not pull the cord.)
  7. Disconnect the engine coolant hoses (A) from throttle body.
    Fig 2: Identifying Engine Coolant Hoses
    G04997332Courtesy of SUBARU OF AMERICA, INC.
  8. Disconnect the brake booster hose (A).
    Fig 3: Identifying Brake Booster Hose
    G04997333Courtesy of SUBARU OF AMERICA, INC.
  9. Disconnect the PCV hose (A) from intake manifold.
  10. Disconnect the engine harness connectors (B) from bulkhead harness connectors.
    Fig 4: Identifying PCV Hose And Engine Harness Connector
    G04997334Courtesy of SUBARU OF AMERICA, INC.
  11. Disconnect the connectors from the engine coolant temperature sensor.
    Fig 5: Identifying Engine Coolant Temperature Sensor
    G04997335Courtesy of SUBARU OF AMERICA, INC.
  12. Disconnect the knock sensor connector.
    Fig 6: Identifying Knock Sensor Connector
    G04997336Courtesy of SUBARU OF AMERICA, INC.
  13. Disconnect the connector from crankshaft position sensor.
    Fig 7: Identifying Crankshaft Position Sensor
    G04997337Courtesy of SUBARU OF AMERICA, INC.
  14. Disconnect the connector from power steering pump switch (A).
  15. Disconnect the connector from the oil pressure switch (B).
    Fig 8: Identifying Power Steering Pump Switch And Oil Pressure Switch
    G05016750Courtesy of SUBARU OF AMERICA, INC.
  16. Disconnect the connector from the camshaft position sensor.
    Fig 9: Identifying Camshaft Position Sensor
    G04997339Courtesy of SUBARU OF AMERICA, INC.
  17. Remove the EGR pipe from intake manifold.
    Fig 10: Identifying EGR Pipe From Intake Manifold
    G05332711Courtesy of SUBARU OF AMERICA, INC.
  18. Disconnect the following connector.
    1. Front oxygen (A/F) sensor connector
    2. Rear oxygen sensor connector
    3. Engine harness connectors
  19. Disconnect the fuel hoses from fuel pipe.
    1. Disconnect the quick connector on the fuel delivery line by pushing the ST in the direction of the arrow. ST 42099AE000 CONNECTOR REMOVER
    2. Remove the clip and disconnect the evaporation hose from the pipe.
    CAUTION:
    • Be careful not to spill fuel.
    • Catch the fuel from hoses using a container or cloth.
      Fig 11: Disconnecting Evaporation Hose From Pipe
      G05339136Courtesy of SUBARU OF AMERICA, INC.
  20. Remove the bolts which secure intake manifold to cylinder head.
    Fig 12: Locating Intake Manifold Bolts
    G04997342Courtesy of SUBARU OF AMERICA, INC.
  21. Remove the intake manifold.
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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.