2020 Subaru Outback BaseFACTORY OEM SERVICE PROCEDURE

Intake Manifold Assembly: Removal

WARNING: This page is about a different variant/trim than selected.
  1. Release the fuel pressure. Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DOTC)>Fuel>PROCEDURE>RELEASING OF FUEL PRESSUREĀ .
  2. Open the fuel filler lid and remove the fuel filler cap.
    NOTE: This operation is required to release the inner pressure of the fuel tank.
  3. Disconnect the ground terminal from battery sensor. Refer to REPAIR CONTENTS>NOTE>BATTERY .
  4. Remove the intercooler. Refer to INTAKE (INDUCTION) (H4DOTC)>Intercooler>REMOVAL .
  5. Remove the intake duct No. 2. Refer to INTAKE (INDUCTION) (H4DOTC)>Intake Duct>REMOVAL>INTAKE DUCT NO. 2 .
  6. When the engine coolant remains before removing the intake manifold assembly
    1. Disconnect the connector (A).
    2. Remove the bolts securing the throttle body and throttle body stay, and move the throttle body aside so that it does not interfere with the work.
    G13198166Courtesy of SUBARU OF AMERICA, INC.
  7. When the engine coolant has been drained before removing the intake manifold assembly
    1. Disconnect the connector (A) from the throttle body, and disconnect the preheater hose (B).
      G13198167Courtesy of SUBARU OF AMERICA, INC.
  8. Disconnect the connector (A) and remove the clip (B).
  9. Disconnect the connector (C) and remove the clip (D).
  10. Remove the PCV pipe from the intake manifold assembly.
    G13619533Courtesy of SUBARU OF AMERICA, INC.
  11. Disconnect the vacuum hose from the check valve.
    G13198169Courtesy of SUBARU OF AMERICA, INC.
  12. Release the lock by sliding the spring, and disconnect the PCV pipe assembly from the intake duct No. 1.
    G13619535Courtesy of SUBARU OF AMERICA, INC.
  13. Remove the connector (A) and connector (B).
  14. Disconnect the fuel delivery tube (C). Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DOTC)>Fuel Delivery and Evaporation Lines>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE A)Ā .
  15. Remove the fuel delivery tube clamp (D).
  16. Disconnect the purge hose (E).
    G13198170Courtesy of SUBARU OF AMERICA, INC.
  17. Remove the V-belt covers.
    G13619537Courtesy of SUBARU OF AMERICA, INC.
  18. Disconnect the connector (A), connector (B), connector (C) and terminal (D), and remove the clip (E) and clip (F).
    G13619538Courtesy of SUBARU OF AMERICA, INC.
  19. Remove the V-belt cover bracket and remove the connector (A).
    G13619539Courtesy of SUBARU OF AMERICA, INC.
  20. Remove the clip (A) securing battery cable assembly and release the claw (B).
    G13619540Courtesy of SUBARU OF AMERICA, INC.
  21. Remove the connector (A) and connector (B) in numerical order shown in figure.
  22. Disconnect the connector (C), and remove the engine wiring harness from the clip (D).
    G13619541Courtesy of SUBARU OF AMERICA, INC.
  23. Release the claw securing the engine wiring harness to the bracket, and place it aside so that it does not interfere with work.
    G13619542Courtesy of SUBARU OF AMERICA, INC.
  24. Remove the V-belts. Refer to MECHANICAL (H4DOTC)>V-belt>REMOVAL>V-BELT .
  25. Remove the fuel pipe protector No. 1.
  26. Loosen the bolt (A) that secure the A/C compressor.
    G13619543Courtesy of SUBARU OF AMERICA, INC.
  27. Remove the fuel pipe protector No. 2.
    G13619544Courtesy of SUBARU OF AMERICA, INC.
  28. Disconnect the connector (A).
  29. Disconnect the fuel delivery pipe (B). Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DOTC)>Fuel Delivery and Evaporation Lines>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE B)Ā .
  30. Remove the clip (C) and clip (D).
    G13619545Courtesy of SUBARU OF AMERICA, INC.
  31. Disconnect the connector (A).
  32. Remove the harness stay.
  33. Remove the harness (B) and clip (C) from the harness stay.
  34. Remove the connector (D) and clip (E).
    G13198179Courtesy of SUBARU OF AMERICA, INC.
  35. Remove the PCV hose. Refer to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DOTC)>PCV Hose>REMOVAL .
  36. Remove the nuts securing the EGR pipe No. 2.
    G13198180Courtesy of SUBARU OF AMERICA, INC.
  37. Remove stud bolt using TORXĀ® socket E5.
    G13198181Courtesy of SUBARU OF AMERICA, INC.
  38. Remove the intake manifold assembly.
    G13619549Courtesy of SUBARU OF AMERICA, INC.
  39. Remove the fuel pipe protector stay.
    NOTE: Perform this procedure only when required.
    G13198184Courtesy of SUBARU OF AMERICA, INC.
  40. Remove the cylinder head plate from cylinder head.
    NOTE: Perform this procedure only when required.
    G13619551Courtesy of SUBARU OF AMERICA, INC.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • ā€¢ You smell fuel, burning insulation, or see smoke.
  • ā€¢ Brakes feel soft, pull hard to one side, or make grinding noises.
  • ā€¢ The engine overheats, stalls repeatedly, or misfires under load.
  • ā€¢ You are missing required tools, torque specs, or safe lifting equipment.
  • ā€¢ You are not confident in the next step or safety outcome.