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Home >> Subaru >> 2009 >> Outback XT Limited, Automatic >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection System (H4DOTC) >> Intake Manifold >> Removal
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Intake Manifold: Removal

  1. Set the vehicle on a lift.
  2. Remove the collector cover.
  3. Collect the refrigerant from A/C system. Refer to PROCEDURE , Refrigerant Recovery Procedure.
  4. Release the fuel pressure. Refer to RELEASING OF FUEL PRESSURE , PROCEDURE, Fuel.
  5. Remove the battery. Refer to REMOVAL , Battery.
  6. Open the fuel filler lid, and remove the fuel filler cap.
  7. Lift up the vehicle.
  8. Remove the under cover.
  9. Drain approximately 3.0 G (3.2 US qt, 2.6 lmp qt) of coolant. Refer to DRAINING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant.
  10. Remove the air intake duct and air cleaner case. Refer to REMOVAL , Air Intake Duct. Refer to REMOVAL , Air Cleaner Case.
  11. Remove the intercooler. Refer to REMOVAL , Intercooler.
  12. Remove the generator. Refer to REMOVAL , Generator.
  13. Remove the coolant filler tank. Refer to REMOVAL , Coolant Filler Tank.
  14. Disconnect the A/C pressure hoses from A/C compressor. Refer to REMOVAL , Hose and Pipe.
  15. Disconnect the vacuum hose (A) and the connector (B) from the PCV hose assembly.
    Fig 1: Identifying Vacuum Hose And Connector
    G05954723Courtesy of SUBARU OF AMERICA, INC.
  16. Remove the connector from the PCV hose assembly.
    Fig 2: Identifying Connector From PCV Hose Assembly
    G05954724Courtesy of SUBARU OF AMERICA, INC.
  17. Remove the bolts which secure the air bypass pipe and PCV pipe to the intake manifold, and loosen the clamp which connects the throttle body and duct.
    Fig 3: Locating Air Bypass Pipe And Bolts
    G05340064Courtesy of SUBARU OF AMERICA, INC.
  18. Remove the duct from the throttle body.
  19. Disconnect the engine coolant hose from throttle body.
    Fig 4: Identifying Engine Coolant Hoses From Throttle Body
    G05954721Courtesy of SUBARU OF AMERICA, INC.
  20. Disconnect the brake booster vacuum hose.
    Fig 5: Identifying Brake Booster Vacuum Hose
    G05954727Courtesy of SUBARU OF AMERICA, INC.
  21. Disconnect the PCV hose from the rocker cover.
    NOTE: Fit the cut out in the ST with the protrusion on the clamp as shown in the figure, unlock the clamp, and disconnect the PCV hose fastened by the clamp.

    ST 18353AA000 CLAMP PLIERS

    Fig 6: Identifying Protrusion On Clamp
    G05340073Courtesy of SUBARU OF AMERICA, INC.
  22. Disconnect the air control hose (A) from the waste gate actuator, and loosen the clamp that holds the turbocharger on the intake duct.
    Fig 7: Identifying Air Control Hose From Waste Gate Actuator
    G06335000Courtesy of SUBARU OF AMERICA, INC.
  23. Disconnect the bulk head harness connectors from the engine harness connector.
    Fig 8: Locating Bulk Head Harness Connectors From Engine Harness Connector
    G05017740Courtesy of SUBARU OF AMERICA, INC.
  24. Remove the engine harness connector from the engine harness bracket.
  25. Disconnect the connectors from the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).
    Fig 9: Identifying Engine Coolant Temperature Sensor, Oil Pressure Switch And Crankshaft Position Sensor
    G04998268Courtesy of SUBARU OF AMERICA, INC.
  26. Disconnect the connector from power steering pump switch.
    Fig 10: Identifying Connector From Power Steering Pump Switch
    G05340076Courtesy of SUBARU OF AMERICA, INC.
  27. Disconnect the knock sensor connector.
    Fig 11: Identifying Knock Sensor Connector
    G05954733Courtesy of SUBARU OF AMERICA, INC.
  28. Disconnect the connector from the secondary air combination valve.
    Fig 12: Identifying Secondary Air Combination Valve
    G05954734Courtesy of SUBARU OF AMERICA, INC.
  29. Disconnect the connector from the camshaft position sensor.
    Fig 13: Identifying Camshaft Position Sensor And Connector
    G05954735Courtesy of SUBARU OF AMERICA, INC.
  30. Disconnect the connector from the oil flow control solenoid valve.
    Fig 14: Identifying Connector From Oil Flow Control Solenoid Valve
    G05954736Courtesy of SUBARU OF AMERICA, INC.
  31. Disconnect the air duct from the secondary air pump, and remove the bolts that install the air duct on the rocker cover LH.
    Fig 15: Locating Rocker Cover LH And Bolts
    G05954737Courtesy of SUBARU OF AMERICA, INC.
  32. Disconnect the connector from ignition coil.
    Fig 16: Locating Connector From Ignition Coil
    G06335009Courtesy of SUBARU OF AMERICA, INC.
  33. Disconnect the connector from the front oxygen (A/F) sensor, and remove the engine harness fixed by clip (A) from the rocker cover, (right side only)
    Fig 17: Locating Connector From Front Oxygen (A/F) Sensor
    G06335010Courtesy of SUBARU OF AMERICA, INC.
  34. Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose.

    ST 42099AE000 QUICK CONNECTOR RELEASE

    CAUTION:
    • Be careful not to spill fuel.
    • Catch the fuel from hoses using a container or cloth.
      Fig 18: Identifying Fuel Delivery Hose, Fuel Return Hose And Evaporation Hose
      G05660529Courtesy of SUBARU OF AMERICA, INC.
  35. Disconnect the fuel return hose using the ST.

    ST 18371AA000 CONNECTOR REMOVER

    CAUTION:
    • Be careful not to spill fuel.
    • Catch the fuel from hoses using a container or cloth.
    1. Attach ST to the fuel return pipe as shown in the figure.
      Fig 19: Attaching ST To Fuel Return Pipe
      G05340084Courtesy of SUBARU OF AMERICA, INC.
    2. Insert the front side of ST into the quick connector.
      Fig 20: Identifying Front Side Of Quick Connector
      G05340085Courtesy of SUBARU OF AMERICA, INC.
    3. Insert the back side of ST into the quick connector and push ST in the direction of arrow mark to disconnect the fuel return hose.
      Fig 21: Locating Back Side Of ST Into Quick Connector
      G05340086Courtesy of SUBARU OF AMERICA, INC.
  36. Remove the clip and disconnect the evaporation hose from the fuel pipe.
    Fig 22: Identifying Evaporation Hose From Fuel Pipe
    G05340087Courtesy of SUBARU OF AMERICA, INC.
  37. Remove the bolts which hold the tumble generator valve assembly onto the cylinder head.
    Fig 23: Locating Tumble Generator Valve Assembly And Bolts
    G05340088Courtesy of SUBARU OF AMERICA, INC.
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