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Home >> Subaru >> 2019 >> Outback 2.5i >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection System (2.5L) >> Intake Manifold Assembly >> Removal
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Intake Manifold Assembly: Removal

  1. Release the fuel pressure. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>Fuel>PROCEDURE>RELEASING OF FUEL PRESSURE .
  2. Disconnect the ground terminal from battery sensor. Ref. to REPAIR CONTENTS>NOTE>BATTERY .
  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 COOLING (H4DO)>ENGINE COOLANT>REPLACEMENT>DRAINING OF ENGINE COOLANT .
  5. Remove the clip (A), and loosen the clamps (B) and (C) securing the air intake boot.
    G11565902Courtesy 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.
    G11565903Courtesy of SUBARU OF AMERICA, INC.
  7. Disconnect the preheater hose from throttle body.
    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.
    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.
    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.
    G10262117Courtesy of SUBARU OF AMERICA, INC.
  14. Remove the air intake duct. Ref. to INTAKE (INDUCTION) (H4DO)>AIR INTAKE DUCT>REMOVAL .
  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.
    G10262118Courtesy of SUBARU OF AMERICA, INC.
  17. Disconnect the connector from the EGR control valve.
    G10262119Courtesy of SUBARU OF AMERICA, INC.
  18. Remove the intake manifold protector RH.
    G10262120Courtesy of SUBARU OF AMERICA, INC.
  19. Remove the clip (A) securing the engine wiring 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.
    G13246681Courtesy of SUBARU OF AMERICA, INC.
    G10262122Courtesy of SUBARU OF AMERICA, INC.
  21. Use a pair of nippers to cut off the tie-wrap (A) securing the engine wiring harness to remove the intake manifold protector LH.
    G12403250Courtesy 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.
    G13246684Courtesy of SUBARU OF AMERICA, INC.
    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.
    G10262126Courtesy of SUBARU OF AMERICA, INC.
  25. Remove the intake manifold assembly from cylinder head.
    G10262127Courtesy of SUBARU OF AMERICA, INC.
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