2009 Subaru Outback XT Limited, AutomaticFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Assembly

  1. Install the tumble generator valve assembly onto intake manifold.
    NOTE: Use new O-rings.

    Tightening torque: 

    8.3 N.m (0.8 kgf-m, 6.1 ft-lb) 

    Fig 1: Locating Tumble Generator Valve Assembly And Bolts
    G05340123Courtesy of SUBARU OF AMERICA, INC.
  2. Install the fuel injector pipe.
  3. Connect fuel hoses to fuel injector pipes on both sides, and secure them with the clamps.

    Tightening torque: 

    1.25 N.m (0.1 kgf-m, 0.9 ft-lb) 

    Fig 2: Identifying Fuel Hose From Pipe
    G05340122Courtesy of SUBARU OF AMERICA, INC.
  4. Tighten the bolts which secure the fuel injector pipe RH to the lower side of the intake manifold.

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 3: Locating Intake Manifold Bolts
    G05340121Courtesy of SUBARU OF AMERICA, INC.
  5. Tighten the bolts which secure fuel injector pipe onto intake manifold.

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 4: Locating Intake Manifold Bolts
    G05340120Courtesy of SUBARU OF AMERICA, INC.
  6. Install the fuel injector.
    • RH side
      Fig 5: Installing Fuel Injector (RH Side)
      G05340118Courtesy of SUBARU OF AMERICA, INC.
    • LH side
      Fig 6: Installing Fuel Injector (LH Side)
      G05340119Courtesy of SUBARU OF AMERICA, INC.
  7. Tighten the bolts which secure fuel injector pipe onto intake manifold.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14.0 ft-lb) 

    • LH side
      Fig 7: Locating Intake Manifold Bolts (LH Side)
      G05340117Courtesy of SUBARU OF AMERICA, INC.
    • RH side
      Fig 8: Locating Intake Manifold Bolts (RH Side)
      G05340116Courtesy of SUBARU OF AMERICA, INC.
  8. Tighten the bolt which holds the fuel injector pipe LH to the front side of the intake manifold, and connect the pressure regulator vacuum hose to the intake manifold.

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 9: Locating Intake Manifold And Bolts
    G06335045Courtesy of SUBARU OF AMERICA, INC.
  9. Install PCV pipe (A), harness assembly (B) and intake duct (C) to the intake manifold.

    Tightening torque: 

    6.5 N.m (0.7 kgf-m, 4.8 ft-lb) 

    Fig 10: Locating PCV Pipe, Harness Assembly And Intake Duct
    G05340114Courtesy of SUBARU OF AMERICA, INC.
  10. Connect the connector to the fuel injector and the tumble generator valve assembly.
    Fig 11: Locating Tumble Generator Valve Assembly
    G05340113Courtesy of SUBARU OF AMERICA, INC.
  11. Install the throttle body to the 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 Bolts
    G05954722Courtesy of SUBARU OF AMERICA, INC.
  12. Connect the connector to the throttle position sensor.
    Fig 13: Locating Connectors From Throttle Position Sensor
    G05954719Courtesy of SUBARU OF AMERICA, INC.
  13. Connect the evaporation hose to the purge control solenoid valve 2.
    NOTE: Connect the evaporation hose as shown in the figure.
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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