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Home >> Subaru >> 2016 >> Outback 2.5i >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection System (H4DO) >> Intake Manifold Assembly >> Removal
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Intake Manifold Assembly: Removal

  1. Release the fuel pressure. < Ref. to RELEASING OF FUEL PRESSURE , PROCEDURE, Fuel. >
  2. Disconnect the ground terminal from battery sensor. < Ref. to BATTERY , NOTE, Repair Contents. >
  3. 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.
  4. Drain approximately 3.0 L (3.2 US qt, 2.6 Imp qt) of coolant. < Ref. to DRAINING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant. >
  5. Remove the clip (A), and loosen the clamps (B) and (C) securing the air intake boot.
    Fig 1: Identifying Air Intake Boot Clip And Clamps
    G10262107Courtesy of SUBARU OF AMERICA, INC.
  6. Remove the air intake boot from the air cleaner case (rear) and throttle body, and move it to the left side wheel apron.
    Fig 2: Identifying Air Cleaner Case (Rear) And Throttle Body
    G10262108Courtesy of SUBARU OF AMERICA, INC.
  7. Disconnect the preheater hose from throttle body.
    Fig 3: Locating Preheater Hose Clamp
    G10262114Courtesy of SUBARU OF AMERICA, INC.
  8. Disconnect the PCV hose (A) from intake manifold assembly.
  9. Disconnect the connector (B) from manifold absolute pressure sensor.
  10. Disconnect the connector (C) from throttle body.
    Fig 4: Identifying Manifold Absolute Pressure Sensor And Throttle Body Connector
    G10262115Courtesy of SUBARU OF AMERICA, INC.
  11. Remove the bolt securing the EGR cooler to the EGR control valve.
  12. Loosen the bolts holding the EGR cooler to the cylinder head RH.
    Fig 5: Identifying EGR Cooler Bolts
    G10262116Courtesy of SUBARU OF AMERICA, INC.
  13. Disconnect the brake booster vacuum hose (A), and disconnect the connector (B) from the purge control solenoid valve.
    Fig 6: Identifying Brake Booster Vacuum Hose And Connector
    G10262117Courtesy of SUBARU OF AMERICA, INC.
  14. Remove the air intake duct. < Ref. to REMOVAL , Air Intake Duct. >
  15. Disconnect the connector (A) from the mass air flow and intake air temperature sensor, and remove the clip (B) securing the bulkhead wiring harness.
  16. Remove the clip (C), and the air cleaner case (rear) together with the air cleaner element.
    Fig 7: Identifying Air Cleaner Case (Rear), Clip And Connector
    G10262118Courtesy of SUBARU OF AMERICA, INC.
  17. Disconnect the connector from the EGR control valve.
    Fig 8: Locating EGR Control Valve Connector
    G10262119Courtesy of SUBARU OF AMERICA, INC.
  18. Remove the intake manifold protector RH.
    Fig 9: Locating Intake Manifold Protector RH Bolt
    G10262120Courtesy of SUBARU OF AMERICA, INC.
  19. Remove the clip (A) securing the engine harness to the intake manifold assembly, and disconnect the connector (B) from the tumble generator valve and disconnect the connector (C) from the fuel injector #3.
  20. Disconnect the fuel delivery pipe from the fuel pipe RH.
    CAUTION:
    • Be careful not to spill fuel.
    • Catch the fuel from the pipes using a container or cloth.
    NOTE: Disconnect the quick connector as shown in the figure.
    Fig 10: Disconnecting Quick Connector
    G10307842Courtesy of SUBARU OF AMERICA, INC.
    Fig 11: Locating Intake Manifold Protector LH Bolt
    G10262122Courtesy of SUBARU OF AMERICA, INC.
  21. Remove the clip (A) securing the engine harness to the intake manifold protector LH to remove the intake manifold protector LH.
    Fig 12: Identifying Engine Harness Clip
    G10262123Courtesy of SUBARU OF AMERICA, INC.
  22. Disconnect the connector (A) from the tumble generator valve, and disconnect the connector (B) from the fuel injector #4.
  23. Disconnect the fuel delivery pipe from the fuel pipe LH.
    CAUTION:
    • Be careful not to spill fuel.
    • Catch the fuel from the pipes using a container or cloth.
    NOTE: Disconnect the quick connector as shown in the figure.
    Fig 13: Disconnecting Connector From Tumble Generator Valve
    G10307845Courtesy of SUBARU OF AMERICA, INC.
    Fig 14: Identifying Tumble Generator Valve And Fuel Injector Connector
    G10262125Courtesy of SUBARU OF AMERICA, INC.
  24. Disconnect the fuel delivery tube and evaporation hose.
    CAUTION:
    • Be careful not to spill fuel.
    • Catch the fuel from the tubes using a container or cloth.
    1. Remove the clip (A) securing the fuel delivery tube.
    2. Attach ST to the fuel pipe assembly and push ST in the direction of arrow mark to disconnect the quick connector of the fuel delivery tube (B).

      ST 42099AE000 QUICK CONNECTOR RELEASE

    3. Disconnect the evaporation hose (C) from the fuel pipe assembly.
      Fig 15: Disconnecting Evaporation Hose From Fuel Pipe Assembly
      G10262126Courtesy of SUBARU OF AMERICA, INC.
  25. Remove the intake manifold assembly from cylinder head.
    Fig 16: Locating Intake Manifold Assembly Bolts
    G10262127Courtesy of SUBARU OF AMERICA, INC.
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