Honda CRV/Odyssey 1995-2000 Repair Information

Intake Manifold

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REMOVAL & INSTALLATION




CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.CRV

  1. Note the radio security code and station presets.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain and recycle the engine coolant.
  6.  
  7. Properly relieve the fuel system pressure, as outlined in Fuel System .
  8.  
  9. If equipped, disconnect the cruise control cable from the throttle linkage.
  10.  
  11. Detach all electrical connectors associated with the throttle body and intake manifold.
  12.  
  13. Remove the intake air hose, throttle cable, and coolant hoses from the throttle body.
  14.  
  15. Remove the two bolts and two nuts mounting the throttle body to the intake manifold.
  16.  
  17. Remove the two intake manifold support brackets.
  18.  
  19. Unbolt the intake manifold and remove it from the cylinder head. Inspect the manifold for cracks or damage to any of the gasket surfaces. Replace if a fault is found.
  20.  

See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the intake manifold- CRV models

To install:

Use new O-rings and gaskets when reassembling.

  1. Clean any old gasket material from the cylinder head, intake manifold, and throttle body.
  2.  
  3. Install a new manifold gasket. Place the manifold into position and support it.
  4.  
  5. Install the support brackets to the manifold. Tighten the bolt holding the brackets to the manifold to 17 ft. lbs. (24 Nm).
  6.  
  7. Starting at the center of the manifold, tighten the nuts in a crisscross pattern to 17 ft. lbs. (24 Nm). The tension must be even across the entire face of the manifold to prevent leaks.
  8.  
  9. Place the throttle body into position and tighten the nuts/bolts to 16 ft. lbs. (22 Nm).
  10.  
  11. The completion of installation is the reverse of the removal procedure.
  12.  
  13. Refill the engine with coolant.
  14.  
  15. Connect the negative battery cable.
  16.  

Odyssey

4-CYLINDER ENGINES
  1. Note the radio security code and station presets.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant into a sealable container.
  6.  
  7. Disconnect the cooling hoses from the intake manifold.
  8.  
  9. Label and disengage the vacuum hoses and electrical connectors on the manifold and throttle body. Unplug the connector from the Exhaust Gas Recirculation (EGR) valve. Position the wiring harnesses out of the way.
  10.  
  11. Disconnect the throttle cable from the throttle body.
  12.  
  13. Disconnect the cruise control cable from the throttle linkage. Unbolt the cable clamp from the valve cover and move the cable out of the way.
  14.  
  15. Relieve the fuel pressure, as outlined in Fuel System .
  16.  


CAUTION
The fuel injection system remains under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Remove the fuel rail and fuel injectors. Refer to Fuel System for procedures.
  2.  
  3. Remove the thermostat housing mounting bolts. Gently pull and twist the thermostat housing to remove it from the intake manifold and the coolant connecting pipe. Discard the O-rings.
  4.  
  5. It may be necessary to remove the upper intake manifold chamber and throttle body assembly in order to access the nuts securing the manifold to the head.
  6.  
  7. Unbolt and remove the intake manifold support bracket. If necessary, raise and support the vehicle safely to reach the manifold support bracket.
  8.  
  9. Loosen the intake manifold nuts in a crisscross pattern starting at the edges and working toward the center of the manifold. Supporting the intake manifold, remove the nuts, then the manifold.
  10.  
  11. Clean any old gasket material from the cylinder head and the intake manifold. Check and clean the chamber and mating surfaces on the cylinder head.
  12.  

See Figure 2

Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the intake manifold and related components-4-cylinder Odyssey models

To install:
  1. Install a new manifold gasket. Place the manifold into position and support it.
  2.  
  3. Install the support bracket to the manifold. Tighten the bolt holding the bracket to the manifold to 16 ft. lbs. (22 Nm).
  4.  
  5. Starting at the center of the manifold, tighten the nuts in a crisscross pattern to 16 ft. lbs. (22 Nm). The tension must be even across the entire face of the manifold to prevent leaks.
  6.  
  7. If the upper intake manifold chamber and throttle body assembly was removed, install it with a new gasket. Tighten the nuts and bolts to 16 ft. lbs. (22 Nm).
  8.  
  9. Install new O-rings onto the coolant connecting pipe and the thermostat housing. Install the housing to the coolant pipe and the intake manifold. Tighten the mounting bolts to 16 ft. lbs. (22 Nm).
  10.  
  11. Connect and adjust the throttle cable.
  12.  
  13. Install the fuel rail and injector assembly. Reconnect the fuel lines using new sealing washers.
  14.  
  15. Properly position the wiring harnesses and engage the electrical connectors.
  16.  
  17. Connect the cruise control cable and place it back into its clamp on the valve cover. Adjust the cruise control cable so there is 0.18-0.22 in. (4.5-5.5mm) of free-play at the linkage.
  18.  
  19. Connect the vacuum hoses.
  20.  
  21. Fill and bleed the air from the cooling system.
  22.  
  23. Connect the negative battery cable and enter the radio security code.
  24.  
  25. Start the engine and check carefully for any fuel, coolant, or vacuum leaks. Check the manifold gasket areas carefully for any vacuum leaks.
  26.  

V6 ENGINE
  1. Note the radio security code and station presets.
  2.  
  3. Disconnect the battery ground cable.
  4.  
  5. Remove the evaporative hose from the throttle body, and the breather pipe and vacuum hose from the intake duct assembly.
  6.  
  7. Remove the intake duct assembly.
  8.  
  9. Remove the intake manifold and ignition coil covers.
  10.  
  11. Remove the throttle and cruise control cables.
  12.  
  13. Remove the brake booster vacuum hoses and the crankcase ventilation hose.
  14.  
  15. Remove the wire harness connections from the intake manifold electrical components.
  16.  
  17. Locate the intake manifold throttle body and remove the water bypass hoses and the breather hose.
  18.  
  19. Remove the intake manifold.
  20.  
  21. Clean any old gasket material from the cylinder head and the intake manifold. Check and clean the chamber and mating surfaces on the cylinder head.
  22.  

See Figure 3

Click image to see an enlarged view

Fig. Fig. 3: Intake manifold tightening sequence-V6 Odyssey models

To install:
  1. Position a new gasket, then install the intake manifold.
  2.  
  3. Tighten the bolts as illustrated in a crisscross pattern from the inside out and torque to 16 ft. lbs. (22 Nm).
  4.  
  5. Locate the intake manifold throttle body and install the water bypass hoses and the breather hose.
  6.  
  7. Install the wire harness connections from the intake manifold electrical components.
  8.  
  9. Install the brake booster vacuum hoses and the crankcase ventilation hose.
  10.  
  11. Install the throttle and cruise control cables.
  12.  
  13. Install the intake manifold and ignition coil covers.
  14.  
  15. Install the intake duct assembly.
  16.  
  17. Install the evaporative hose to the throttle body, and the breather pipe and vacuum hose to the intake duct assembly.
  18.  
  19. Reconnect the negative battery cable.
  20.  
  21. Enter the security code for the radio.
  22.  
  23. Check and top off all fluid levels and check for any fluid leaks.
  24.  

 
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