Subaru Outback manuals

Subaru Outback: Intake Manifold

A: REMOVAL

1. INTAKE MANIFOLD

1) Release the fuel pressure.

2) Disconnect the ground cable from battery.

Subaru Outback. Fuel Injection (Fuel Systems)

3) Open the fuel filler lid and remove the fuel filler cap.

4) Remove the cover (A) and clip (B) from air intake boot assembly.

Subaru Outback. Fuel Injection (Fuel Systems)

5) Loosen the clamp (A) which connects the air intake boot assembly and air cleaner case.

6) Loosen the clamp (B) which connects the air intake boot assembly and throttle body.

Subaru Outback. Fuel Injection (Fuel Systems)

7) Remove the air intake boot from the throttle body, and move it to the left side wheel apron.

Subaru Outback. Fuel Injection (Fuel Systems)

8) Disconnect the connector from the ignition coil of #3 cylinder.

Subaru Outback. Fuel Injection (Fuel Systems)

9) Remove the intake manifold protector RH.

Subaru Outback. Fuel Injection (Fuel Systems)

10) Remove the connector (A) from the fuel injector, and remove the fuel delivery pipe (B) from the fuel gallery RH.

NOTE: Disconnect the quick connector as shown in the figure.

Subaru Outback. Fuel Injection (Fuel Systems)

  1. Slider

Subaru Outback. Fuel Injection (Fuel Systems)

11) Disconnect the fuel delivery hose (A) and evaporation hose (B).

CAUTION:

  1. Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the quick connector of the fuel delivery hose (A).

ST 42099AE000 QUICK CONNECTOR RELEASE

  1. Remove the clip and disconnect the evaporation hose (B) from the pipe.

Subaru Outback. Fuel Injection (Fuel Systems)

12) Remove the generator cable clip (A) from the intake manifold protector LH.

13) Remove the oil filler pipe (B) from the rocker cover LH.

14) Disconnect the brake booster vacuum hose (C).

Subaru Outback. Fuel Injection (Fuel Systems)

15) Disconnect the connector from the ignition coil of #2 cylinder.

Subaru Outback. Fuel Injection (Fuel Systems)

16) Remove the intake manifold protector LH.

Subaru Outback. Fuel Injection (Fuel Systems)

17) Remove the connector (A) from the fuel injector, and remove the fuel delivery pipe (B) from the fuel gallery LH.

NOTE: Disconnect the quick connector as shown in the figure.

Subaru Outback. Fuel Injection (Fuel Systems)

  1. Slider

Subaru Outback. Fuel Injection (Fuel Systems)

18) Remove the clip (A) securing the engine harness to the intake manifold, and remove the bolt (B) securing the LH side of the multifunction duct assembly.

Subaru Outback. Fuel Injection (Fuel Systems)

19) Remove the bolts (A) which secure the RH side of multi-function duct assembly to the intake manifold.

20) Remove the cap (B) from the intake manifold.

Subaru Outback. Fuel Injection (Fuel Systems)

21) Remove the intake manifold from cylinder head.

22) Remove the fuel gallery RH and fuel injector from the intake manifold.

Subaru Outback. Fuel Injection (Fuel Systems)

23) Remove the fuel gallery LH, fuel pipe and fuel injector from the intake manifold.

Subaru Outback. Fuel Injection (Fuel Systems)

2. MULTI-FUNCTION DUCT ASSEMBLY

1) Release the fuel pressure.

2) Disconnect the ground cable from battery.

Subaru Outback. Fuel Injection (Fuel Systems)

3) Open the fuel filler lid and remove the fuel filler cap.

4) Lift up the vehicle.

5) Remove the under cover.

6) Drain approximately 3.0 Subaru Outback. Fuel Injection (Fuel Systems) (3.2 US qt, 2.6 Imp qt) of coolant.

7) Lower the vehicle.

8) Remove the intake manifold.

9) Remove the bolt, and disconnect the bulkhead harness connector from the engine harness connector and rear engine hanger.

Subaru Outback. Fuel Injection (Fuel Systems)

10) Slide the engine harness connector in the direction of the arrow and remove it from the rear engine hanger.

Subaru Outback. Fuel Injection (Fuel Systems)

11) Disconnect the connector from the knock sensor.

Subaru Outback. Fuel Injection (Fuel Systems)

12) Disconnect the water hose (A) and EGR pipe (B) from the LH side of multi-function duct assembly.

Subaru Outback. Fuel Injection (Fuel Systems)

13) Disconnect the water hose from the RH side of multi-function duct assembly.

Subaru Outback. Fuel Injection (Fuel Systems)

14) Disconnect the connector (A) from the engine coolant temperature sensor, and disconnect the terminal (B) from oil pressure switch and the connector (C) from the crankshaft position sensor.

Subaru Outback. Fuel Injection (Fuel Systems)

15) Disconnect the connector (A) from front oxygen (A/F) sensor and the connector (B) from the rear oxygen sensor.

16) Disconnect the connector (C) from the ignition coil of #1 cylinder.

17) Disconnect the connector (D) from the oil switching solenoid valve RH, disconnect the connector (E) from the oil temperature sensor RH, disconnect the connector (F) from the variable valve lift diagnosis switch and disconnect the ground terminal (G) from the rear engine hanger.

Subaru Outback. Fuel Injection (Fuel Systems)

18) Slide the front oxygen (A/F) sensor connector and rear oxygen sensor connector in the direction of the arrow and remove them from the bracket.

Subaru Outback. Fuel Injection (Fuel Systems)

19) Disconnect the connector from the ignition coil of #4 cylinder.

20) Disconnect the connector (A) from the oil switching solenoid valve LH and the connector (B) from the camshaft position sensor LH.

Subaru Outback. Fuel Injection (Fuel Systems)

21) Remove the bolt (A) securing the multi-function duct assembly to the PCV pipe, and remove the multi-function duct assembly.

22) Remove the clip (B) securing the engine harness to the PCV pipe, and remove the engine harness.

Subaru Outback. Fuel Injection (Fuel Systems)

B: INSTALLATION

1. INTAKE MANIFOLD

Install in the reverse order of removal while being careful of the following.

CAUTION:

Subaru Outback. Fuel Injection (Fuel Systems)

NOTE:

Tightening torque:
T1: 6.4 N*m (0.7 kgf-m, 4.7 ft-lb)
T2: 19 N*m (1.9 kgf-m, 14.0 ft-lb)

Subaru Outback. Fuel Injection (Fuel Systems)

Tightening torque: 6.4 N*m (0.7 kgf-m, 4.7 ft-lb)

Subaru Outback. Fuel Injection (Fuel Systems)

Tightening torque: 25 N*m (2.5 kgf-m, 18.4 ft-lb)

Subaru Outback. Fuel Injection (Fuel Systems)

Tightening torque: 6.4 N*m (0.7 kgf-m, 4.7 ft-lb)

Subaru Outback. Fuel Injection (Fuel Systems)

NOTE: Align the clamp hole with the protrusion of the air intake boot assembly.

Subaru Outback. Fuel Injection (Fuel Systems)

Tightening torque:
Clamp (A), (B)
3 N*m (0.3 kgf-m, 2.2 ft-lb)

Subaru Outback. Fuel Injection (Fuel Systems)

2. MULTI-FUNCTION DUCT ASSEMBLY

Install in the reverse order of removal.

NOTE:

Subaru Outback. Fuel Injection (Fuel Systems)

  1. Front side of vehicle

Tightening torque: 1.5 N*m (0.2 kgf-m, 1.1 ft-lb)

Subaru Outback. Fuel Injection (Fuel Systems)

Tightening torque: 6.4 N*m (0.7 kgf-m, 4.7 ft-lb)

Subaru Outback. Fuel Injection (Fuel Systems)

Tightening torque: 19 N*m (1.9 kgf-m, 14.0 ft-lb)

Subaru Outback. Fuel Injection (Fuel Systems)

C: INSPECTION

1) Check that the intake manifold and fuel pipe have no deformation, cracks and other damages.

2) Check that the hose has no cracks, damage or loose part.

Engine Coolant Temperature Sensor

A: REMOVAL

1) Disconnect the ground cable from battery.

Subaru Outback. Fuel Injection (Fuel Systems)

2) Remove the generator.

3) Drain engine coolant.

4) Disconnect the connector (A) from the engine coolant temperature sensor, and remove the engine coolant temperature sensor.

Subaru Outback. Fuel Injection (Fuel Systems)

B: INSTALLATION

Install in the reverse order of removal.

NOTE: Use a new gasket.

Tightening torque: 18 N*m (1.8 kgf-m, 13.3 ft-lb)

C: INSPECTION

1) Check that the engine coolant temperature sensor has no deformation, cracks or other damages.

2) Immerse the engine coolant temperature sensor and a thermometer in water.

CAUTION: Take care not to allow water to get into the engine coolant temperature sensor connector.

Completely remove any water inside.

Subaru Outback. Fuel Injection (Fuel Systems)

  1. Thermometer
  2. Engine coolant temperature sensor
  3. Hexagonal part height: To approx.1/3

3) Raise water temperature gradually, measure the resistance between the engine coolant temperature sensor terminals when the temperature is 20ºC (68ºF) and 80ºC (176ºF).

NOTE: Agitate the water for even temperature distribution.

Subaru Outback. Fuel Injection (Fuel Systems)

READ NEXT:

 Crankshaft Position Sensor

A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the bolt which secures crankshaft position sensor to oil pump. 3) Remove the crankshaft position sensor, and disconnect the connecto

 Knock Sensor

A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the cover (A) and clip (B) from air intake boot assembly. 3) Loosen the clamp (A) which connects the air intake boot assembly and ai

 Manifold Absolute Pressure Sensor

A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the cover (A) and clip (B) from air intake boot assembly. 3) Loosen the clamp (A) which connects the air intake boot assembly and ai

SEE MORE:

 DTC 41, 42, 45, 46, 4A, 4B, 4D, 4E, 53, 54, 55, 58, 59, 5A, 5B, 5C, 5D, 61, 62, 65, 66, 6A, 6B, 6D, 6E

W: DTC 41 SIDE AIRBAG RH FAILURE NOTE: Be sure to properly identify the Airbag system type prior to performing any diagnostics. 1. TYPE A DTC DETECTING CONDITION: Side airbag harness (RH) is faulty. Side airbag module (RH) is faulty. Airbag control module is faulty. CAUTION: Before performing

 Front passenger’s frontal airbag ON and OFF indicators

The front passenger’s frontal airbag ON and OFF indicators show you the status of the front passenger’s SRS frontal airbag. The indicators are located next to the clock in the center portion of the dashboard. When the ignition switch is turned to the “ON” position, both the ON and

© 2010-2021 Copyright www.suoutback.com