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Home >> Subaru >> 2003 >> Outback L.L. Bean Edition >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection (Fuel Systems, H6DO) >> Intake Manifold >> Assembly
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Intake Manifold: Assembly

  1. Install induction valve vacuum hose to intake manifold.
    Fig 1: Installing Induction Valve Vacuum Hose To Intake Manifold
    G02877094Courtesy of SUBARU OF AMERICA, INC.
  2. Install fuel pipe and injector pipe assembly.
    1. Tightening torque:  5.0 N.m (0.51 kgf-m, 3.7 ft-lb)
  3. Connect pressure regulator vacuum hose (A) to intake manifold.
    Fig 2: Connecting Pressure Regulator Vacuum Hose To Intake Manifold (1 Of 2)
    G02877095Courtesy of SUBARU OF AMERICA, INC.
    Fig 3: Connecting Pressure Regulator Vacuum Hose To Intake Manifold (2 Of 2)
    G02877096Courtesy of SUBARU OF AMERICA, INC.
  4. Install air assist and purge pipe assembly.
    Fig 4: Installing Air Assist & Purge Pipe Assembly
    G02877097Courtesy of SUBARU OF AMERICA, INC.
    1. Tightening torque:  5.0 N.m (0.51 kgf-m, 3.7 ft-lb)
  5. Install PCV pipe to intake manifold.

    Tightening torque: 

    1. 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 
    Fig 5: Installing PCV Pipe To Intake Manifold
    G02877098Courtesy of SUBARU OF AMERICA, INC.
  6. Install engine harness assembly to intake manifold.
    1. Tightening torque:  5.0 N.m (0.51 kgf-m, 3.7 ft-lb)
    Fig 6: Installing Engine Harness Assembly To Intake Manifold
    G02877099Courtesy of SUBARU OF AMERICA, INC.
  7. Install EGR valve.
    1. Tightening torque:  19 N.m (1.9 kgf-m, 14 ft-lb)
  8. Connect connector to EGR valve.
    Fig 7: Connecting Connector To EGR Valve
    G02877100Courtesy of SUBARU OF AMERICA, INC.
  9. Install purge control solenoid valve.
    1. Tightening torque:  19 N.m (1.9 kgf-m, 14 ft-lb)
  10. Connect connector to purge control solenoid valve.
    Fig 8: Connecting Connector To Purge Control Solenoid Valve
    G02877101Courtesy of SUBARU OF AMERICA, INC.
  11. Connect hoses to purge control solenoid valve.
    CAUTION: Carefully connect the evaporation hoses.
    Fig 9: Connecting Hoses To Purge Control Solenoid Valve
    G02877102Courtesy of SUBARU OF AMERICA, INC.
  12. Install induction valve control solenoid.
    1. Tightening torque:  19 N.m (1.9 kgf-m, 14 ft-lb)
  13. Connect connector to induction valve control solenoid.
    Fig 10: Connecting Connector To Induction Valve Control Solenoid
    G02877103Courtesy of SUBARU OF AMERICA, INC.
  14. Install induction valve.
    1. Tightening torque:  19 N.m (1.9 kgf-m, 14 ft-lb)
    Fig 11: Installing Induction Valve
    G02877104Courtesy of SUBARU OF AMERICA, INC.
  15. Connect hoses to induction valve control solenoid.
    CAUTION: Carefully connect the vacuum hoses.
    Fig 12: Connecting Hoses To Induction Valve Control Solenoid
    G02877105Courtesy of SUBARU OF AMERICA, INC.
  16. Install throttle body to intake manifold.
    NOTE: Replace gasket with a new one.
    1. Tightening torque:  22 N.m (2.2 kgf-m, 15.9 ft-lb)
    Fig 13: Installing Throttle Body To Intake Manifold
    G02877106Courtesy of SUBARU OF AMERICA, INC.
  17. Connect connectors to throttle position sensor.
    Fig 14: Connecting Connectors To Throttle Position Sensor
    G02877107Courtesy of SUBARU OF AMERICA, INC.
  18. Connect connectors to intake manifold pressure sensor (A) and idle air control solenoid valve (B).
  19. Connect air by-pass hose (C) to idle air control solenoid valve.
    Fig 15: Connecting Air By-Pass Hose To Idle Air Control Solenoid Valve
    G02877108Courtesy of SUBARU OF AMERICA, INC.
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