Subaru 14011AB940 Manifold Assembly Intake

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To remove the intake manifold, first relieve the fuel pressure and disconnect the cable from the negative terminal of the battery. Remove the engine cover if equipped, and take out the air filler housing, resonator, and air intake ducts as needed for access. On non-turbo models, detach the spark plug wires from the ignition coil, then clamp off and disconnect the coolant hoses from the throttle body, placing a rag underneath to catch any residual coolant. Disconnect the electrical connectors from the fuel injectors and other sensors, labeling them for correct reassembly. Remove the power steering pump and alternator, positioning them aside without disconnecting fluid lines. Remove the air conditioning compressor and its mounting bracket similarly. Disconnect the PCV hose and all vacuum lines from the intake manifold, labeling them for reassembly. Disconnect the fuel delivery and return hoses from the fuel rail, keeping the injectors attached. For non-turbocharged models, remove the EGR pipe and valve if equipped, and disconnect the accelerator and cruise control cables on specific model years. Remove the air assist injector solenoid valve and bracket, disconnect the air filter housing brace, and remove the intake manifold mounting bolts, carefully lifting the manifold off the engine with the throttle body attached. For 2004 and 2005 Legacy/Outback models, disconnect the connectors from the tumble generator valve position sensor and actuator, then remove the lower intake manifold mounting bolts. For ULEV models, disconnect the electrical connector from the throttle body, remove the EGR pipe and valve, and disconnect various hoses before lifting the manifold off the engine. For turbocharged models, disconnect the electronic throttle control system, remove the intercooler, and disconnect the oil flow control solenoid valve connector and vacuum hoses before lifting the upper intake manifold off the engine. When installing, scrape away any old gasket materials and clean the surfaces, using new gaskets or O-rings without sealant. Carefully place the lower intake manifold onto each cylinder head and install the mounting bolts, tightening them evenly. For ULEV models, if the manifold was removed as a complete unit, place it onto the engine and install the mounting bolts, or if disassembled, assemble the pieces lightly before installation. For turbocharged models, place the lower intake manifolds onto the cylinder heads and bolt them into place, then place the upper intake manifold onto the lower and install the mounting bolts. Finally, install the fuel rail and injectors, attach the PCV valve hose, install the oil fill lube and bracket, connect the EGR supply pipe if equipped, and reconnect all wiring connectors and hoses, checking for any damage. Connect the coolant hoses and radiator hose, adjust the accelerator cable if applicable, and check the coolant level, adding as necessary before starting the engine and checking for leaks.

Yes, for non-turbo models, you should also remove the EGR pipe and valve, air assist injector solenoid valve, and air filter housing brace as part of the removal process.

To remove the intake manifold, you'll need to remove the intake manifold mounting bolts and then lift the manifold off the engine. During installation, it's important to clean the mounting surfaces, use new gaskets, and tighten the bolts in steps. Attach various components and hoses, including the fuel rail and injectors, PCV valve hose, EGR supply pipe, wiring connectors, vacuum and fuel hoses, and coolant and radiator hoses. Additionally, adjust the accelerator cable if necessary. Check for leaks and refill coolant as needed.