Honda - Accord Prelude 1996 2000

Intake Manifold

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REMOVAL & INSTALLATION



The radio may contain a coded theft protection circuit. Always obtain the code number before disconnecting the battery.

2.2L and 2.3L Engines


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Fig. It is recommended to use a closed-end wrench to remove the intake manifold-to-cylinder head bolts



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Fig. Intake manifold and related components-2.3L engine shown

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant into a sealable container.
  4.  
  5. Disconnect the cooling hoses from the intake manifold.
  6.  
  7. Label and unplug the vacuum hoses and electrical connectors on the manifold and throttle body. Unplug the connector from the EGR valve. Position the wiring harnesses out of the way.
  8.  
  9. Disconnect the throttle cable from the throttle body.
  10.  
  11. Relieve the fuel pressure, as outlined in Fuel System .
  12.  
  13. Remove the fuel rail and fuel injectors.
  14.  
  15. Remove the thermostat housing mounting bolts. Remove the thermostat housing from the intake manifold and the connecting pipe by pulling and twisting the housing. Discard the O-rings.
  16.  
  17. It may be necessary to remove the upper intake manifold plenum and throttle body assembly in order to access the nuts securing the manifold to the head.
  18.  
  19. Remove the intake manifold support bracket bolts and the bracket. If it is necessary to access it from under the vehicle; raise and support the vehicle safely.
  20.  
  21. While supporting the intake manifold, remove the nuts attaching the intake manifold to the cylinder head, then remove the manifold. Remove the old gasket from the cylinder head.
  22.  
  23. Clean any old gasket material from the cylinder head and the intake manifold. Check and clean the FIA chamber on the cylinder head.
  24.  

To install:

  1. Using a new gasket, place the manifold into position and support.
  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 with the inner or center nuts, tighten the nuts, in a crisscross pattern, to the correct torque. The tension must be even across the entire face of the manifold if leaks are to be prevented. Correct torque is 16 ft. lbs. (22 Nm).
  6.  
  7. Using a new gasket, install the upper intake manifold and throttle body assembly, if removed as a separate unit. Tighten the nuts and bolts holding the chamber to 16 ft. lbs. (22 Nm).
  8.  
  9. Install a new O-ring to the coolant connecting pipe, and to 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/injector assembly. Connect the fuel lines.
  14.  
  15. Properly position the wiring harnesses and attach the electrical connectors, as tagged during removal.
  16.  
  17. Connect the vacuum hoses, as tagged during removal.
  18.  
  19. Fill and bleed the air from the cooling system.
  20.  
  21. Connect the negative battery cable and enter the radio security code.
  22.  
  23. Start the engine and check carefully for any leaks of fuel, coolant or vacuum. Check the manifold gasket areas carefully for any leakage of vacuum.
  24.  

2.7L Engines


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Fig. Exploded view of the intake manifold and related components-2.7L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant into a sealable container.
  4.  
  5. Relieve the fuel pressure, as outlined in Fuel System .
  6.  
  7. Disconnect the feed hose from the fuel filter.
  8.  
  9. Remove the PCV valve from the rocker arm (valve) cover.
  10.  
  11. Remove the air intake duct.
  12.  
  13. Remove the intake manifold covers.
  14.  
  15. Remove the throttle cable and cruise control cable by loosening the locknut, then slip the cable end out of the accelerator linkage.
  16.  
  17. Label and unplug all electrical connections on the manifold and throttle body.
  18.  
  19. Disconnect the hoses from the brake booster and the evaporative canister.
  20.  
  21. Remove the wiring harness holders and position them out of the way.
  22.  
  23. Disconnect the vacuum hose from the fuel pressure regulator.
  24.  
  25. Remove the fuel rail attaching nuts.
  26.  
  27. Remove the fuel rail from the injectors, leaving the injectors in the manifold.
  28.  
  29. Remove each injector, noting its position, and remove the seal ring from each manifold port.
  30.  
  31. Remove the cushion ring and O-ring from each injector.
  32.  
  33. Label and disconnect all vacuum and coolant hoses from the intake manifold and throttle body. If necessary, remove the vacuum pipe assembly.
  34.  
  35. Remove the EGR crossover pipe. Discard the gasket.
  36.  
  37. Remove the bolts and nuts securing the intake manifold to the engine. Be sure all vacuum and electrical connections are unplugged. Carefully lift the manifold from the engine. Discard the gaskets.
  38.  

To install:

  1. Using new gaskets, place the manifold into position. Install the nuts/bolts until just snug.
  2.  
  3. Starting with the inner/center bolts, tighten the nuts and bolts in a crisscross pattern to the correct torque. The tension must be even across the entire face of the manifold if leaks are to be prevented. Correct torque is 16 ft. lbs. (22 Nm).
  4.  
  5. Install the EGR crossover pipe using a new gasket. Tighten the nuts (to the intake manifold) to 108 inch lbs. (12 Nm) and the pipe (to the exhaust manifold) to 43 ft. lbs. (59 Nm).
  6.  
  7. If removed, install the vacuum pipe assembly. Tighten the bolts to 108 inch lbs. (12 Nm).
  8.  
  9. Connect the coolant hoses to the intake manifold and the throttle body.
  10.  
  11. Install new cushion rings on each injector.
  12.  
  13. Coat new O-rings with clean engine oil and install them on the fuel injectors.
  14.  
  15. Install the injectors into the fuel rail. Make certain the O-rings seat properly and are not distorted.
  16.  

Assembling each injector into the fuel rail prevents damage to the O-rings. Handle the rail and injector assembly carefully when reinstalling it to the manifold. Don't drop the injectors or bang their tips.

  1. Coat new seal rings with a light coat of clean, thin oil and install them into the manifold.
  2.  
  3. Install the fuel rail and injectors to the intake manifold.
  4.  
  5. With all injectors seated in the manifold, be sure each injector is positioned properly.
  6.  
  7. Install the fuel rail retaining nuts and tighten them evenly to 108 inch lbs. (12 Nm).
  8.  
  9. Connect the vacuum hose to the regulator.
  10.  
  11. Install the wiring harness to the fuel rail and tighten the mounting bolts to 108 inch lbs. (12 Nm).
  12.  
  13. Connect the electrical harness to the injectors.
  14.  
  15. Attach all electrical and vacuum connections to the throttle body and manifold.
  16.  
  17. Connect the brake booster, evaporative canister, and fuel return hoses.
  18.  
  19. Connect the feed hose to the fuel filter with new gaskets. Tighten the union bolt to 16 ft. lbs. (22 Nm) and the service bolt to 108 inch lbs. (12 Nm).
  20.  
  21. Install and adjust the throttle and cruise control cables.
  22.  
  23. Install the air intake duct.
  24.  
  25. Install the PCV valve to the rocker arm (valve) cover.
  26.  
  27. Refill and bleed the air from the cooling system.
  28.  
  29. Connect the negative battery cable and enter the radio security code.
  30.  
  31. Switch the ignition ON but do not engage the starter. The fuel pump should run for approximately 2 seconds, building pressure within the lines. Switch the ignition OFF , then ON 2 or 3 more times to build full system pressure. Check for fuel leaks.
  32.  
  33. Start the engine and check carefully for any leaks of fuel, coolant, or vacuum. Check the manifold gasket areas carefully for any leakage of vacuum.
  34.  
  35. Install the intake manifold covers and tighten the attaching bolts to 108 inch lbs. (12 Nm).
  36.  

3.0L Engine
  1. Obtain the security code for the radio.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the coolant into a suitable container.
  6.  
  7. Disconnect the EVAP canister hose from the throttle body.
  8.  
  9. Remove the air intake duct.
  10.  
  11. Remove the upper engine covers.
  12.  
  13. Disconnect the accelerator and cruise control cables from the throttle body.
  14.  
  15. Ensure that all components have been removed from the intake manifold.
  16.  
  17. Unfasten the retaining bolts, then remove the intake manifold.
  18.  

To install:

  1. Clean the mounting surfaces.
  2.  
  3. Install a new gasket on the engine and install the manifold.
  4.  
  5. Starting with the inner/center bolts, tighten the nuts and bolts in a crisscross pattern to the correct torque. The tension must be even across the entire face of the manifold if leaks are to be prevented. Correct torque is 16 ft. lbs. (22 Nm).
  6.  
  7. Install all removed hoses and wiring on the intake manifold and throttle body.
  8.  
  9. Install the engine covers.
  10.  
  11. Install the intake air duct.
  12.  
  13. Refill the cooling system.
  14.  
  15. Connect the negative battery cable, start the engine, and check for leaks.
  16.  



Click image to see an enlarged view

Fig. Exploded view of the intake manifold and related components-3.0L engine

 
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