Honda Civic/CRX/del Sol 1984-1995 Repair Guide

Intake Manifold

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REMOVAL & INSTALLATION



1984-87 Carbureted Engines

See Figure 1

  1. Place a clean pan under the radiator, remove the drain plug and drain the cooling system. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner and case.
  4.  
  5. Refer to the "Carburetor, Removal and Installation" procedures in Fuel System and remove the carburetor from the intake manifold.
  6.  
  7. Remove the emission control hoses from the manifold T-joint; one hose leads to the condensation chamber and the other leads to the charcoal canister.
  8.  
  9. Remove the hose connected to the intake manifold directly above the T-joint and underneath the carburetor, leading to the air cleaner check valve (refer to Fuel System for diagrams of the various emission control hose connections).
  10.  
  11. Remove the electrical connectors from the thermoswitches.
  12.  
  13. Remove the solenoid valve located next to the thermoswitch.
  14.  
  15. Remove the intake manifold-to-cylinder head nuts in a crisscross pattern, beginning from the center and moving out to both ends, then, remove the manifold.
  16.  
  17. Using a putty knife, clean the gasket mounting surfaces of the manifold and the cylinder head.
  18.  

To install:
  1. If the intake manifold is to be replaced, transfer all necessary components to the new manifold.
  2.  
  3. To install, use new gaskets, sealant (if necessary) and reverse the removal procedure, being sure to observe the following points:
    1. Apply a water-resistant sealer to the new intake manifold gasket before positioning it in place.
    2.  
    3. Be sure all hoses are properly connected.
    4.  
    5. Tighten the manifold nuts in a crossing pattern, from the inside nuts outward. Tighten the nuts to 16 ft. lbs (22 Nm).
    6.  
    7. When installing the carburetor, replace the carburetor insulator gasket and O-ring. Tighten the carburetor mounting nuts to 16 ft. lbs. (22 Nm).

      Click image to see an enlarged view

      Fig. Fig. 1: Intake manifold and components-1984-87 carbureted engines

    8.  

  4.  

1985-91 Fuel Injected Models (All)

See Figures 2, 3 and 4

  1. Disconnect the negative battery cable. Drain the cooling system, into a suitable container.
  2.  
  3. Label and disconnect all related electrical connectors and vacuum lines.
  4.  
  5. Properly relieve the fuel system pressure (Refer to Fuel System for the correct procedure.)
  6.  
  7. Remove the throttle body assembly on 1.5L engines with dual-point fuel injection. On all other engines, remove the fuel injector manifold and fuel injectors.
  8.  
  9. As required, remove the fast idle control valve, the air bleed valve, the EGR valve and all related brackets.
  10.  
  11. Remove the intake manifold retaining bolts. Remove the intake manifold assembly from the vehicle. Discard the gaskets.
  12.  



Click image to see an enlarged view

Fig. Fig. 2: Intake manifold and components-1984-87 multi-port fuel injected engines



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Fig. Fig. 3: Intake manifold, throttle body and related components-1988-91 DP-FI engines



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Fig. Fig. 4: Exploded view of the intake manifold and related components-1988-91 MPFI engines

1984-87 multi-port fuel injected engines have a bolt-together upper and lower manifold chamber. Separate the upper chamber from the lower manifold before removing the assembly from the vehicle.

To install:
  1. Installation is the reverse of the removal procedure.
  2.  
  3. Make sure all gasket mating surfaces are clean prior to installation.
  4.  
  5. Always use new gaskets.
  6.  
  7. Tighten the intake manifold nuts in 2-3 steps in a crisscross pattern starting with the inside nuts. Tighten the nuts to 16 ft. lbs. (22 Nm).
  8.  
  9. On 1984-87 models attach the upper manifold to the lower manifold and tighten the 6mm bolts and nut to 9 ft. lbs. (12 Nm) and the 8mm bolt to 16 ft. lbs. (22 Nm).
  10.  
  11. Make sure that all hoses and wires are connected properly.
  12.  
  13. Refill the cooling system.
  14.  

1992-95 Engines

See Figures 5 and 6

  1. Disconnect the negative battery cable. Drain the cooling system, into a suitable container.
  2.  
  3. Label and disconnect all related electrical connectors and vacuum lines.
  4.  
  5. Properly relieve the fuel system pressure (Refer to Fuel System for the correct procedure.)
  6.  
  7. Remove the fuel injector manifold and four individual fuel injectors.
  8.  
  9. As required, remove the fast idle control valve, the air bleed valve, the EGR valve and all related brackets.
  10.  
  11. Remove the intake manifold retaining bolts. Remove the intake manifold assembly from the vehicle. Discard the gaskets.
  12.  



Click image to see an enlarged view

Fig. Fig. 5: Intake manifold design and proximal components-1992-95 D16Z6 and D15B7 engines



Click image to see an enlarged view

Fig. Fig. 6: Intake manifold design and proximal components-1992-95 D15Z1 AND D15B8 engines

To install:
  1. Installation is the reverse of the removal procedure.
  2.  
  3. Make sure all gasket mating surfaces are clean prior to installation.
  4.  
  5. Always use new gaskets.
  6.  
  7. Tighten the intake manifold nuts in 2-3 steps in a crisscross pattern starting with the inside nuts. Tighten the nuts to 17 ft. lbs. (23 Nm).
  8.  
  9. Make sure that all hoses and wires are connected properly.
  10.  
  11. Refill the cooling system.
  12.  

 
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