2009 Subaru Outback i, AutomaticFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Removal

  1. Set the vehicle on a lift.
  2. Release the fuel pressure. Refer to RELEASING OF FUEL PRESSURE , PROCEDURE, Fuel.
  3. Disconnect the ground cable from battery.
    Fig 1: Disconnecting Ground Cable From Battery
    G05019586Courtesy of SUBARU OF AMERICA, INC.
  4. Open the fuel filler lid, and remove the fuel filler cap.
  5. Lift up the vehicle.
  6. Remove the under cover.
  7. Drain approximately 3.0 fi (3.2 US qt, 2.6 lmp qt) of coolant. Refer to DRAINING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant.
  8. Remove the air intake duct and air intake chamber. Refer to REMOVAL , Air Intake Duct. Refer to REMOVAL , Air Intake Chamber.
  9. Remove the generator. Refer to REMOVAL , Generator.
  10. Disconnect the spark plug cord from the spark plug.
  11. Disconnect the engine coolant hoses (A) from throttle body.
    Fig 2: Identifying Engine Coolant Hoses
    G04997332Courtesy of SUBARU OF AMERICA, INC.
  12. Disconnect the brake booster vacuum hose (A).
    Fig 3: Identifying Brake Booster Vacuum Hose
    G04997333Courtesy of SUBARU OF AMERICA, INC.
  13. Disconnect the PCV hose (A) from intake manifold.
    Fig 4: Identifying PCV Hose
    G05953678Courtesy of SUBARU OF AMERICA, INC.
  14. Remove the bolt, and disconnect the bulk head harness connector from the engine harness connector and rear engine hanger.
    Fig 5: Locating Bulk Head Harness Connector Bolt
    G05953679Courtesy of SUBARU OF AMERICA, INC.
  15. Slide the engine harness connector in the direction of the arrow and remove the rear engine hanger.
    Fig 6: Identifying Engine Harness Connector Sliding Direction
    G05953680Courtesy of SUBARU OF AMERICA, INC.
  16. Disconnect the connectors from the engine coolant temperature sensor.
    Fig 7: Identifying Engine Coolant Temperature Sensor Connectors
    G04997335Courtesy of SUBARU OF AMERICA, INC.
  17. Disconnect the knock sensor connector.
    Fig 8: Identifying Knock Sensor Connector
    G04997336Courtesy of SUBARU OF AMERICA, INC.
  18. Disconnect the connector from crankshaft position sensor.
    Fig 9: Identifying Crankshaft Position Sensor Connector
    G04997337Courtesy of SUBARU OF AMERICA, INC.
  19. Disconnect the connector from power steering pump switch (A).
  20. Disconnect the connector from the oil pressure switch (B).
    Fig 10: Identifying Power Steering Pump Switch Connector And Oil Pressure Switch Connector
    G05659390Courtesy of SUBARU OF AMERICA, INC.
  21. Disconnect the connector from the camshaft position sensor.
    Fig 11: Identifying Camshaft Position Sensor Connector
    G04997339Courtesy of SUBARU OF AMERICA, INC.
  22. Disconnect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B).
    Fig 12: Identifying Front Oxygen (A/F) Sensor Connector And Rear Oxygen Sensor Connector
    G04997794Courtesy of SUBARU OF AMERICA, INC.
  23. Disconnect the connector from the oil switching solenoid valve.
  24. Disconnect the connector from the variable valve lift diagnosis oil pressure switch.
    • LH side
      Fig 13: Locating Variable Valve Lift Diagnosis Oil Pressure Switch Connector - LH Side
      G04997419Courtesy of SUBARU OF AMERICA, INC.
    • RH side
      Fig 14: Locating Variable Valve Lift Diagnosis Oil Pressure Switch Connector - RH Side
      G04997420Courtesy of SUBARU OF AMERICA, INC.
  25. Disconnect the connector from the oil temperature sensor.
    Fig 15: Locating Oil Temperature Sensor Connector
    G04997421Courtesy of SUBARU OF AMERICA, INC.
  26. Remove the EGR pipe from intake manifold.
    Fig 16: Identifying EGR Pipe
    G05332711Courtesy of SUBARU OF AMERICA, INC.
  27. 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 QUICK CONNECTOR RELEASE

    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 17: Disconnecting Quick Connector On Fuel Delivery Line By Pushing ST In Direction Of Arrow
        G05018407Courtesy of SUBARU OF AMERICA, INC.
  28. Remove the bolts which secure intake manifold to cylinder head.
    Fig 18: Locating Bolts Which Secure Intake Manifold To Cylinder Head
    G05659394Courtesy of SUBARU OF AMERICA, INC.
  29. Remove the intake manifold.
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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