Honda Pilot - 2003-2005

Intake Manifold

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Removal & Installation



2003-04 Models
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold cover
     
    Air intake tube
     
    Throttle and cruise control cables
     

  4.  
  5. Remove the following electrical connections and clamps from the manifold:

    Intake Air Temperature (IAT) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Throttle Position (TP) sensor connector
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Evaporative Emissions (EVAP) control canister purge valve connector
     
    Brake booster vacuum line
     
    Positive Crankcase Ventilation (PCV) hose
     
    Water bypass hoses from the throttle body and plug the hoses
     
    EVAP control canister hose
     

  6.  
  7. Remove or disconnect the following:

    Upper cover bolts and nuts in the sequence illustrated using two or three passes
     
    Intake manifold bolts using two or three passes
     
    Intake manifold and spacer

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold-2003-04 models

     

  8.  

To install:

Click image to see an enlarged view

Fig. Intake manifold torque sequence-2003-04 models



Click image to see an enlarged view

Fig. Upper cover torque sequence-2003-04 models

  1. Install or connect the following:

    New intake manifold gasket and spacer
     
    Intake manifold. Tighten the fasteners in sequence and in several passes to 16 ft. lbs. (22 Nm).
     
    Upper cover bolts and nuts in the sequence illustrated using two or three passes to 9 ft. lbs. (12 Nm)
     
    EVAP control canister hose
     
    Water bypass hoses toe throttle body
     
    Brake booster vacuum line
     
    PCV hose
     

  2.  
  3. Connect the following electrical connections and clamps to the manifold:

    EVAP control canister purge valve connector
     
    MAP sensor connector
     
    TP sensor connector
     
    IAC valve connector
     
    IAT sensor connector
     
    Throttle and cruise control cables
     
    Air intake tube
     
    Intake manifold cover
     
    Negative battery cable
     

  4.  
  5. Start the engine and check for proper operation.
  6.  

2005 Models
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold cover
     
    Intake Air Temperature (IAT) sensor 2 connector
     
    Air intake tube
     
    Positive Crankcase Ventilation (PCV) hose
     
    Brake booster vacuum line
     
    Evaporative Emissions (EVAP) control canister hose and transmission breather hose clamp bracket
     
    Water bypass hoses from the throttle body and plug the hoses
     

  4.  
  5. Remove the following electrical connections and clamps from the manifold:

    Intake Air Temperature (IAT) sensor connector
     
    Throttle Position (TP) sensor connector
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    EVAP canister purge valve connector
     
    Upper cover bolts and nuts in the sequence illustrated using two or three passes
     
    Intake manifold bolts in the sequence illustrated
     
    Intake manifold and spacer

    Click image to see an enlarged view

    Fig. Upper cover loosening sequence-2005 models



    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold-2005 models



    Click image to see an enlarged view

    Fig. Intake manifold loosening sequence-2005 models

     

  6.  

To install:

Click image to see an enlarged view

Fig. Intake manifold torque sequence-2005 models



Click image to see an enlarged view

Fig. Upper cover torque sequence-2005 models

  1. Install or connect the following:

    New intake manifold gasket and spacer
     
    Intake manifold. Tighten the fasteners in sequence and in several passes to 16 ft. lbs. (22 Nm).
     
    Upper cover bolts and nuts in the sequence illustrated using two or three passes to 9 ft. lbs. (12 Nm)
     

  2.  
  3. Connect the following electrical connections and clamps to the manifold:

    EVAP canister purge valve connector
     
    MAP sensor connector
     
    TP sensor connector
     
    IAT sensor 1 connector
     
    Water bypass hoses to the throttle body
     
    EVAP control canister hose and clamp bracket
     
    Intake manifold vacuum line
     
    Brake booster vacuum line
     
    PCV hose
     
    Air intake tube
     
    IAT sensor 2 connector
     
    Intake manifold cover
     
    Negative battery cable
     

  4.  
  5. Start the engine and check for proper operation.
  6.  

 
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