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Home >> Subaru >> 2022 >> Outback Base >> 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. If the fuel delivery tube is disconnected after removing the intake manifold assembly, perform the following work.
    1. Release the fuel pressure. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL>PROCEDURE>RELEASING OF FUEL PRESSURE .
    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. 

  2. Disconnect the ground terminal from battery sensor. Ref. to REPAIR CONTENTS>NOTE>BATTERY .
  3. Disconnect the positive terminal of battery.
  4. Remove the V-belt covers.
    G13618354Courtesy of SUBARU OF AMERICA, INC.
  5. Remove the clip from the air intake boot, and loosen the clamp.
    G13618350Courtesy of SUBARU OF AMERICA, INC.
  6. Remove the air intake boot, and place it aside so that it does not interfere with the work.
    CAUTION:

    Be careful not to pull out the PCV hose. 

    G13618351Courtesy of SUBARU OF AMERICA, INC.
  7. 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 move the throttle body aside so that it does not interfere with the work.
    G13618357Courtesy of SUBARU OF AMERICA, INC.
  8. When the engine coolant has been drained before removing the intake manifold assembly
    1. Disconnect the connector (A), and disconnect the preheater hose (B).
    G13618358Courtesy of SUBARU OF AMERICA, INC.
  9. Disconnect the connector (A).
  10. Disconnect the purge hose (B).
  11. Disconnect the PCV hose No. 1 (C).
  12. Remove the bolt securing the fuel pipe.
    G13618359Courtesy of SUBARU OF AMERICA, INC.
  13. Disconnect the connector (A).
  14. Remove the fuel delivery tube clamp (B).
  15. Remove the clip (C).
    G13223832Courtesy of SUBARU OF AMERICA, INC.
  16. Remove the nut (A) securing the EGR Cooler.
  17. Remove stud bolt (B) using TORX® E8.
  18. Loosen the bolt (C) holding the EGR cooler.
    G13618361Courtesy of SUBARU OF AMERICA, INC.
  19. Disconnect the connector (A), connector (B), connector (C) and terminal (D), and remove the clip (E) and clip (F).
    G13618362Courtesy of SUBARU OF AMERICA, INC.
  20. Remove the connector (A) and connector (B).
    G13618363Courtesy of SUBARU OF AMERICA, INC.
  21. Disconnect the brake booster vacuum hose (A).
  22. Disconnect the connector (B), and remove the engine wiring harness from the clip (C).
  23. Remove the clip (D) securing battery cable assembly and release the claw (E).
    G13618364Courtesy of SUBARU OF AMERICA, INC.
  24. Disconnect the connector.
    G13618365Courtesy of SUBARU OF AMERICA, INC.
  25. Cut off the part (A) of the clip with a pair of nippers, and remove the engine wiring harness from the intake manifold assembly.
    G13618366Courtesy of SUBARU OF AMERICA, INC.
  26. Disconnect connector (A) from ECM. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>ENGINE CONTROL MODULE (ECM)>REMOVAL .
  27. Disconnect the connector (B) from the main fuse box, and remove the engine wiring harness from the clip (C).
    G13618367Courtesy of SUBARU OF AMERICA, INC.
  28. Remove the claw (A) securing the battery cable assembly to the bracket, and place it aside so that it does not interfere with work.
  29. Release the claw (B) securing the engine wiring harness to the bracket, and place it aside so that it does not interfere with work.
    G13618368Courtesy of SUBARU OF AMERICA, INC.
  30. Remove the fuel pipe protector.
    G13618369Courtesy of SUBARU OF AMERICA, INC.
  31. Remove the fuel delivery tube.
    G13223842Courtesy of SUBARU OF AMERICA, INC.
  32. Remove the intake manifold assembly.
    G13618371Courtesy of SUBARU OF AMERICA, INC.
  33. Remove the tape (B) that covers the band part of the clip (A) on the engine wiring harness.
    CAUTION:

    Be careful not to remove the tape wrapped under the band part of the clip. 

    G13618372Courtesy of SUBARU OF AMERICA, INC.
  34. Cut off the band part of the clip with a pair of nippers.
    NOTE:

    Put alignment marks (a) on the band part of the clip and on the engine wiring harness. 

    G13618373Courtesy of SUBARU OF AMERICA, INC.
  35. Remove the cylinder head plate.
    NOTE:

    Perform this procedure when required. 

    G13618374Courtesy of SUBARU OF AMERICA, INC.
  36. Disconnect the fuel delivery pipe. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE C) .
    G13618375Courtesy of SUBARU OF AMERICA, INC.
  37. Disconnect the fuel delivery pipe (A). Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE B) .
  38. Disconnect the fuel delivery tube (B). Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE A) .
  39. Remove the clip (C) from the fuel pipe.
G13618376Courtesy of SUBARU OF AMERICA, INC.
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