2009 Subaru Outback LimitedFACTORY 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, 18.4 ft-lb) 

    Fig 1: Locating Bolts Which Secure Intake Manifold To Cylinder Head
    G05659394Courtesy of SUBARU OF AMERICA, INC.
  2. Connect the fuel delivery hose and evaporation hose to the fuel pipe. Refer to INSTALLATION , Fuel Delivery and Evaporation Lines.
    NOTE: If fuel hoses or clamps are damaged, replace them with new parts.
  3. Install the EGR pipe to intake manifold.

    Tightening torque: 

    34 N.m (3.5 kgf-m, 25.1 ft-lb) 

    Fig 2: Identifying EGR Pipe
    G05332711Courtesy of SUBARU OF AMERICA, INC.
  4. Connect the connector to the oil temperature sensor.
    Fig 3: Locating Oil Temperature Sensor Connector
    G04997421Courtesy of SUBARU OF AMERICA, INC.
  5. Connect the connector to the variable valve lift diagnosis oil pressure switch.
    • LH side
      Fig 4: Locating Variable Valve Lift Diagnosis Oil Pressure Switch Connector - LH Side
      G04997419Courtesy of SUBARU OF AMERICA, INC.
    • RH side
      Fig 5: Locating Variable Valve Lift Diagnosis Oil Pressure Switch Connector - RH Side
      G04997420Courtesy of SUBARU OF AMERICA, INC.
  6. Connect the connector to the oil switching solenoid valve.
  7. Connect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B).
    Fig 6: Identifying Front Oxygen (A/F) Sensor Connector And Rear Oxygen Sensor Connector
    G04997794Courtesy of SUBARU OF AMERICA, INC.
  8. Connect the connectors to camshaft position sensor.
    Fig 7: Identifying Camshaft Position Sensor Connectors
    G04997339Courtesy of SUBARU OF AMERICA, INC.
  9. Connect the connector to the power steering pump switch (A).
  10. Connect the connector to the oil pressure switch (B).
    Fig 8: Identifying Power Steering Pump Switch Connector And Oil Pressure Switch Connector
    G05659390Courtesy of SUBARU OF AMERICA, INC.
  11. Connect the connector to crankshaft position sensor.
    Fig 9: Identifying Crankshaft Position Sensor Connector
    G04997337Courtesy of SUBARU OF AMERICA, INC.
  12. Connect the knock sensor connector.
    Fig 10: Identifying Knock Sensor Connector
    G04997336Courtesy of SUBARU OF AMERICA, INC.
  13. Connect the connector to engine coolant temperature sensor.
    Fig 11: Identifying Engine Coolant Temperature Sensor Connectors
    G04997335Courtesy of SUBARU OF AMERICA, INC.
  14. Connect the PCV hose (A) to intake manifold.
    Fig 12: Identifying PCV Hose
    G05953678Courtesy of SUBARU OF AMERICA, INC.
  15. Connect the brake booster hose (A).
    Fig 13: Identifying Brake Booster Hose
    G04997333Courtesy of SUBARU OF AMERICA, INC.
  16. Connect the engine harness connector to the bulkhead harness connector and fasten to the rear engine hanger with bolt.

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 14: Locating Bulk Head Harness Connector Bolt
    G05953679Courtesy of SUBARU OF AMERICA, INC.
  17. Connect the engine coolant hoses (A) to throttle body.
    Fig 15: Identifying Engine Coolant Hoses
    G04997332Courtesy of SUBARU OF AMERICA, INC.
  18. Connect the spark plug cords to spark plugs.
  19. Install the generator. Refer to INSTALLATION , Generator.
  20. Install the air intake duct and air intake chamber. Refer to INSTALLATION , Air Intake Duct. Refer to INSTALLATION , Air Intake Chamber.
  21. Connect the ground cable to battery.
    Fig 16: Disconnecting Ground Cable From Battery
    G05019586Courtesy of SUBARU OF AMERICA, INC.
  22. Lift up the vehicle.
  23. Install the under cover.
  24. Lower the vehicle.
  25. Fill engine coolant. Refer to DRAINING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant.
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.