Honda Prelude Accord Civic S2000 2001-2006

Intake Manifold

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Removal & Installation



1.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following: Negative battery cable

    Negative battery cable
     

  4.  
  5. Drain the cooling system to a level below the upper radiator hose.
  6.  
  7. Relieve the fuel system pressure by loosening the fuel filter service bolt.
  8.  


CAUTION
The fuel injection system remains under pressure even after the engine has been turned off. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and personal injury.

  1. Remove or disconnect the following: Intake air ductAir cleaner assembly, if equipped with the D16Y7 engine

    Intake air duct
     
    Air cleaner assembly, if equipped with the D16Y7 engine
     

  2.  


NOTE
Cover the throttle body opening to keep dirt out.



Fuel line from the fuel rail. Clean up any spilled fuel.
 
Fuel injector wiring harnesses
 
Fuel rail and injectors
 
Throttle cable from the linkage at the throttle body
 
Intake manifold cooling hoses. Use a drain pan to catch any spilled coolant. Also, be sure no coolant spills on electrical connections.
 


NOTE
Label all electrical connectors before detaching them.



Engine wiring harness connectors from the intake manifold sensors
 
Idle Air Control (IAC) valve
 
Exhaust Gas Recirculation (EGR valve), if equipped
 
Throttle Position (TP) and Manifold Absolute Pressure (MAP) sensor
 
Manifold from its support bracket
 
Intake manifold nuts in a crisscross pattern.
 
Intake manifold assembly from the vehicle.
 



Click image to see an enlarged view

Fig. Exploded view of the intake manifold and related components-1.7L engines

To install:


NOTE
Use new gaskets when installing the intake manifold. Use new O-rings when installing manifold sensors and components. Use new sealing washers when reconnecting the fuel lines.

  1. Clean all gasket mating surfaces.
  2.  
  3. Install or connect the following: New intake manifold gasketsIntake manifold

    New intake manifold gaskets
     
    Intake manifold
     

  4.  
  5. Tighten the intake manifold nuts in 2 or 3 steps in a crisscross pattern starting with the inside nuts. Tighten the nuts to 16 ft. lbs. (22 Nm).
  6.  
  7. Install or connect the following: Support bracket bolts: 17 ft. lbs. (24 Nm)Fuel rail and injectorsFuel line using new washersEGR valve and tighten its nuts to 15 ft. lbs. (21 Nm).IAC valve. Tighten its mounting bolts to 16 ft. lbs. (22 Nm).Fuel injector wiring harnessesIntake manifold wiring harnessesIntake manifold cooling hosesThrottle cableIntake air duct and air cleaner assembly

    Support bracket bolts: 17 ft. lbs. (24 Nm)
     
    Fuel rail and injectors
     
    Fuel line using new washers
     
    EGR valve and tighten its nuts to 15 ft. lbs. (21 Nm).
     
    IAC valve. Tighten its mounting bolts to 16 ft. lbs. (22 Nm).
     
    Fuel injector wiring harnesses
     
    Intake manifold wiring harnesses
     
    Intake manifold cooling hoses
     
    Throttle cable
     
    Intake air duct and air cleaner assembly
     

  8.  
  9. Refill and bleed the cooling system.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Verify that all sensors, valves, and vacuum lines are installed and connected properly. Be sure there are no loose electrical connections.
  14.  
  15. Turn the ignition on and off several times without starting the engine to pressurize the fuel system. Run the engine and check for proper operation. Check for vacuum leaks.
  16.  
  17. After the engine has warmed up, check the operation of the throttle cable and adjust it if necessary.
  18.  

2.0L Engines


Click image to see an enlarged view

Fig. Exploded view of the intake manifold-2.0L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following: Negative battery cableCooling hoses from the intake manifoldVacuum hoses and electrical connectors from the manifold and throttle bodyThrottle cable from the throttle bodyFuel rail and fuel injectorsIntake manifold support bracketsIntake manifold

    Negative battery cable
     
    Cooling hoses from the intake manifold
     
    Vacuum hoses and electrical connectors from the manifold and throttle body
     
    Throttle cable from the throttle body
     
    Fuel rail and fuel injectors
     
    Intake manifold support brackets
     
    Intake manifold
     

  8.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values: Intake manifold fasteners: 16 ft. lbs. (22 Nm)Throttle body fasteners: 16 ft. lbs. (22 Nm)Intake manifold bracket bolts: 33 ft. lbs. (44 Nm)

    Intake manifold fasteners: 16 ft. lbs. (22 Nm)
     
    Throttle body fasteners: 16 ft. lbs. (22 Nm)
     
    Intake manifold bracket bolts: 33 ft. lbs. (44 Nm)
     

  2.  

2.2L & 2.3L Engines


Click image to see an enlarged view

Fig. Intake manifold and related components-2.3L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant into a sealable container.
  6.  
  7. Remove or disconnect the following: Cooling hoses from the intake manifold

    Cooling hoses from the intake manifold
     

  8.  


NOTE
Label all vacuum hoses and electrical connectors before detaching them.



Vacuum hoses and electrical connectors from the manifold and throttle body
 
Connector from the Exhaust Gas Recirculation (EGR) valve. Position the wiring harnesses out of the way.
 
Throttle cable from the throttle body
 

  1. Relieve the fuel pressure.
  2.  
  3. Remove or disconnect the following: Fuel rail and fuel injectorsThermostat housing from the intake manifold and the connecting pipe by pulling and twisting the housing. Discard the O-rings.

    Fuel rail and fuel injectors
     
    Thermostat housing from the intake manifold and the connecting pipe by pulling and twisting the housing. Discard the O-rings.
     

  4.  


NOTE
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.



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.
 

  1. 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.
  2.  
  3. Clean any old gasket material from the cylinder head and the intake manifold. Check and clean the FIA chamber on the cylinder head.
  4.  

To install:

  1. Install or connect the following: New gasketIntake manifold, and support the manifold.Support bracket to the manifold. Tighten the retaining bolt to 16 ft. lbs. (22 Nm).

    New gasket
     
    Intake manifold, and support the manifold.
     
    Support bracket to the manifold. Tighten the retaining bolt to 16 ft. lbs. (22 Nm).
     

  2.  
  3. 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).
  4.  
  5. Install or connect the following: New gasketUpper 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).New O-ring to the coolant connecting pipe, and to the thermostat housing.Housing to the coolant pipe and the intake manifold. Tighten the mounting bolts to 16 ft. lbs. (22 Nm).Throttle cable and adjust.Fuel rail/injector assemblyFuel linesWiring harnesses and the electrical connectorsVacuum hoses

    New gasket
     
    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).
     
    New O-ring to the coolant connecting pipe, and to the thermostat housing.
     
    Housing to the coolant pipe and the intake manifold. Tighten the mounting bolts to 16 ft. lbs. (22 Nm).
     
    Throttle cable and adjust.
     
    Fuel rail/injector assembly
     
    Fuel lines
     
    Wiring harnesses and the electrical connectors
     
    Vacuum hoses
     

  6.  
  7. Fill and bleed the air from the cooling system.
  8.  
  9. Connect the negative battery cable and enter the radio security code.
  10.  
  11. 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.
  12.  
  13. If equipped with 4WS, turn the steering wheel lock-to-lock to reset the 4WS control unit.
  14.  

2.4L Engine
3.0L Engine
Accord
2.3L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant into a sealable container.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Label all vacuum hoses and electrical connectors before detaching them.



    Cooling hoses from the intake manifold
     



    Vacuum hoses and electrical connectors from the manifold and throttle body
     
    Connector from the Exhaust Gas Recirculation (EGR) valve. Position the wiring harnesses out of the way.
     
    Throttle cable from the throttle body
     

  8.  
  9. Relieve the fuel pressure.
  10.  
  11. Remove or disconnect the following:
    NOTE
    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.



    Fuel rail and fuel injectors
     
    Thermostat housing from the intake manifold and the connecting pipe by pulling and twisting the housing. Discard the O-rings.
     



    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.
     

  12.  
  13. 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.
  14.  
  15. Clean any old gasket material from the cylinder head and the intake manifold. Check and clean the FIA chamber on the cylinder head.

    Click image to see an enlarged view

    Fig. Intake manifold and related components-2.3L engine

  16.  

To install:

  1. Install or connect the following:

    New gasket
     
    Intake manifold, and support the manifold.
     
    Support bracket to the manifold. Tighten the retaining bolt to 16 ft. lbs. (22 Nm).
     

  2.  
  3. 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).
  4.  
  5. Install or connect the following:

    New gasket
     
    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).
     
    New O-ring to the coolant connecting pipe, and to the thermostat housing.
     
    Housing to the coolant pipe and the intake manifold. Tighten the mounting bolts to 16 ft. lbs. (22 Nm).
     
    Throttle cable and adjust.
     
    Fuel rail/injector assembly
     
    Fuel lines
     
    Wiring harnesses and the electrical connectors
     
    Vacuum hoses
     

  6.  
  7. Fill and bleed the air from the cooling system.
  8.  
  9. Connect the negative battery cable and enter the radio security code.
  10.  
  11. 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.
  12.  

2.4L Engine

NOTE
Make sure to acquire the anti-theft code from the radio and write down the frequencies for the radio-s preset buttons.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant into a sealable container.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Do not bend the cables during removal. Always replace any throttle or cruise control cables that get kinked during removal.



    Intake Air Temperature (IAT) sensor electrical connector
     
    Vacuum hose and breather pipe and the air intake duct
     
    Intake manifold cover

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold and related components-2.4L engine

     
    Throttle and cruise control cables by loosening the locknuts, then slipping the cable ends out of the accelerator linkage.
     



    Evaporative emission (EVAP) canister hose and brake booster vacuum hose
     
    Idle Air Control (IAC) valve connectors
     
    Throttle Position (TP) sensor connector
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Necessary engine wire harness connectors and wire harness clamps from the intake manifold
     
    Bolt securing the harness holder and remove the harness clamps
     
    Water bypass hoses, then plug them
     
    Harness clamp and harness connector from the intake manifold bracket
     
    Intake manifold bracket
     
    A/T vacuum hose
     
    Retainer and intake manifold
     

  8.  

To install:

  1. Clean the mounting surfaces.
  2.  
  3. Install or connect the following:

    New gasket
     
    Intake manifold. Tighten the bolts, in a crisscross pattern beginning with the inner bolt, to 16 ft. lbs. (22 Nm).
     
    A/T vacuum hose
     
    Intake manifold bracket
     
    Harness clamp and connector to the intake manifold bracket
     
    Water bypass hoses
     
    Bolt securing the harness holder and tighten to 8.7 ft. lbs. (12 Nm)
     
    Harness clamps
     
    EVAP canister hose and brake booster vacuum hose
     
    Throttle and cruise control cables
     
    Intake manifold cover
     
    Intake air duct
     
    IAT sensor connector, vacuum hose and breather pipe
     

  4.  
  5. Refill the cooling system.
  6.  
  7. Connect the negative battery cable, start the engine, and check for leaks.
  8.  
  9. Reprogram the power window control unit as follows.
  10.  
  11. Turn the ignition switch ON. Lower the window, all the way down. Open the driver-s side door.
  12.  
  13. Turn the ignition switch OFF. Push and hold the drivers window DOWN switch. Turn the ignition switch ON. Release the driver-s window DOWN switch. This must be done within five seconds.
  14.  
  15. Repeat the above step three more times. Wait one second.
  16.  
  17. Confirm that the AUTO UP and AUTO DOWN do not work. If they work repeat the procedure, paying close attention to the five second time limit
  18.  
  19. Move the driver-s window all the way down by holding the drivers window DOWN switch to the AUTO DOWN position.
  20.  
  21. Pull up and hold the driver-s window UP switch to the AUTO UP position until the window reaches the fully closed position. Hold the switch for one second.
  22.  
  23. Confirm that the power window master switch has been reset by using the driver-s window AUTO UP and DOWN function.
  24.  
  25. If the AUTO UP and DOWN feature is still not working, repeat the complete procedure, paying close attention to the five second time limit.
  26.  

2001-02 3.0L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Obtain the security code for the radio.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the coolant.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Ensure that all components have been removed from the intake manifold.



    Evaporative emissions (EVAP) canister hose from the throttle body.
     
    Air intake duct
     
    Upper engine covers
     
    Accelerator and cruise control cables from the throttle body.
     



    Intake manifold
     

  10.  

To install:

  1. Clean the mounting surfaces.
  2.  
  3. Install or connect the following:

    New gasket
     
    Intake manifold. Tighten the bolts to 16 ft. lbs. (22 Nm).
     
    All removed hoses and wiring on the intake manifold and throttle body.
     
    Engine covers
     
    Intake air duct
     

  4.  
  5. Refill the cooling system.
  6.  
  7. Connect the negative battery cable, start the engine, and check for leaks.

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold and related components-2001-01 Accord with 3.0L engine

  8.  

2003-06 3.0L Engine

NOTE
Make sure to acquire the anti-theft code from the radio and write down the frequencies for the radio-s preset buttons.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure. Disconnect the negative battery cable. Drain the cooling system.
  4.  
  5. Remove the ignition coil cover. Remove the breather pipe and the air intake duct.
  6.  
  7. Remove the PCV valve hose, power brake booster hose, evaporative emission canister hose and the vacuum hose.
  8.  
  9. Remove the water bypass hoses. Remove the engine wire harness connectors and the wire harness clamps from the intake manifold
  10.  
  11. Disconnect the intake air temperature sensor connector, throttle actuator connector and the manifold absolute sensor connector.
  12.  
  13. Disconnect the evaporative emission canister purge valve connector and the engine mount control solenoid valve connector.
  14.  
  15. Disconnect the intake manifold tuning runner control actuator connector, if equipped with manual transaxle.
  16.  
  17. Remove the upper cover mounting bolts sequentially in two or three steps and remove the upper cover.
  18.  
  19. Remove the intake manifold retaining bolts sequentially in two or three steps. Remove the intake manifold and spacer from the engine.
  20.  

To install:


NOTE
Use new gaskets when installing the intake manifold. Use new O-rings when installing manifold sensors and components. Use new sealing washers when reconnecting the fuel lines.

  1. Clean all gasket mating surfaces.
  2.  
  3. Torque the intake manifold retaining nuts to specification, sequentially in two or three steps.
  4.  
  5. Torque the upper cover retaining bolts to 8.7 ft. lbs. (12 Nm), sequentially in two or three steps.
  6.  
  7. Continue the installation in the reverse order of the removal procedure.
  8.  
  9. Reprogram the power window control unit as follows.
  10.  
  11. Turn the ignition switch ON. Lower the window, all the way down. Open the driver-s side door.
  12.  
  13. Turn the ignition switch OFF. Push and hold the drivers window DOWN switch. Turn the ignition switch ON. Release the driver-s window DOWN switch. This must be done within five seconds.
  14.  
  15. Repeat the above step three more times. Wait one second.
  16.  
  17. Confirm that the AUTO UP and AUTO DOWN do not work. If they work repeat the procedure, paying close attention to the five second time limit
  18.  
  19. Move the driver-s window all the way down by holding the drivers window DOWN switch to the AUTO DOWN position.
  20.  
  21. Pull up and hold the driver-s window UP switch to the AUTO UP position until the window reaches the fully closed position. Hold the switch for one second.
  22.  
  23. Confirm that the power window master switch has been reset by using the driver-s window AUTO UP and DOWN function.
  24.  
  25. If the AUTO UP and DOWN feature is still not working, repeat the complete procedure, paying close attention to the five second time limit.
  26.  

Civic
1.8L Engine

NOTE
Make sure to acquire the anti-theft code from the radio and write down the frequencies for the radio-s preset buttons.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Disconnect the negative battery cable. Drain the cooling system.
  4.  
  5. Remove the cowl cover and the under cowl panel. Remove the air cleaner housing assembly. Remove the air intake duct.
  6.  
  7. Remove the injector cover. Remove the evaporative emission canister hose, power brake booster hose and the power steering pump hose clamp.
  8.  
  9. Remove the quick connect fitting cover. Disconnect the fuel feed hose.
  10.  
  11. Remove the engine wire harness connectors and the wire harness clamps from the intake manifold.
  12.  
  13. Disconnect the throttle actuator connector, the manifold absolute pressure connector, the evaporative emission control canister purge connector and the intake manifold tuning valve actuator connector.
  14.  
  15. Remove the water bypass hoses. Remove the throttle body. Remove the heater hose clamp bracket.
  16.  
  17. Raise and safely support the vehicle. Remove the intake manifold bracket. Lower the vehicle.
  18.  
  19. Remove the intake manifold retaining bolts. Remove the intake manifold from the engine.
  20.  

To install:


NOTE
Use new gaskets when installing the intake manifold. Use new O-rings when installing manifold sensors and components. Use new sealing washers when reconnecting the fuel lines.

  1. Clean all gasket mating surfaces.
  2.  
  3. Torque the intake manifold retaining nuts to 17 ft. lbs. (24 Nm).
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  
  7. Reprogram the power window control unit as follows.
  8.  
  9. Turn the ignition switch ON. Lower the window, all the way down. Open the driver-s side door.
  10.  
  11. Turn the ignition switch OFF. Push and hold the drivers window DOWN switch. Turn the ignition switch ON. Release the driver-s window DOWN switch. This must be done within five seconds.
  12.  
  13. Repeat the above step three more times. Wait one second.
  14.  
  15. Confirm that the AUTO UP and AUTO DOWN do not work. If they work repeat the procedure, paying close attention to the five second time limit
  16.  
  17. Move the driver-s window all the way down by holding the drivers window DOWN switch to the AUTO DOWN position.
  18.  
  19. Pull up and hold the driver-s window UP switch to the AUTO UP position until the window reaches the fully closed position. Hold the switch for one second.
  20.  
  21. Confirm that the power window master switch has been reset by using the driver-s window AUTO UP and DOWN function.
  22.  
  23. If the AUTO UP and DOWN feature is still not working, repeat the complete procedure, paying close attention to the five second time limit.
  24.  

2001-03 GX 1.7L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     

  4.  
  5. Drain the cooling system to a level below the upper radiator hose.
  6.  
  7. Relieve the fuel system pressure by loosening the fuel filter service bolt.
    CAUTION
    The fuel injection system remains under pressure even after the engine has been turned off. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and personal injury.

  8.  
  9. Remove or disconnect the following:
    NOTE
    Cover the throttle body opening to keep dirt out.


    NOTE
    Label all electrical connectors before detaching them.



    Intake air duct
     



    Fuel line from the fuel rail. Clean up any spilled fuel.
     
    Fuel injector wiring harnesses
     
    Fuel rail and injectors
     
    Throttle cable from the linkage at the throttle body
     
    Intake manifold cooling hoses. Use a drain pan to catch any spilled coolant. Also, be sure no coolant spills on electrical connections.
     



    Engine wiring harness connectors from the intake manifold sensors
     
    Idle Air Control (IAC) valve
     
    Exhaust Gas Recirculation (EGR valve), if equipped
     
    Throttle Position (TP) and Manifold Absolute Pressure (MAP) sensor
     
    Manifold from its support bracket
     
    Intake manifold nuts in a crisscross pattern.
     
    Intake manifold assembly from the vehicle.

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold and related components-1.7L engine except 2001-03 GX

     

  10.  

To install:


NOTE
Use new gaskets when installing the intake manifold. Use new O-rings when installing manifold sensors and components. Use new sealing washers when reconnecting the fuel lines.

  1. Clean all gasket mating surfaces.
  2.  
  3. Install or connect the following:

    New intake manifold gaskets
     
    Intake manifold
     

  4.  
  5. Tighten the intake manifold nuts in 2 or 3 steps in a crisscross pattern starting with the inside nuts. Tighten the nuts to 16 ft. lbs. (22 Nm).
  6.  
  7. Install or connect the following:

    Support bracket bolts: 17 ft. lbs. (24 Nm)
     
    Fuel rail and injectors
     
    Fuel line using new washers
     
    EGR valve and tighten its nuts to 15 ft. lbs. (21 Nm).
     
    IAC valve. Tighten its mounting bolts to 16 ft. lbs. (22 Nm).
     
    Fuel injector wiring harnesses
     
    Intake manifold wiring harnesses
     
    Intake manifold cooling hoses
     
    Throttle cable
     
    Intake air duct and air cleaner assembly
     

  8.  
  9. Refill and bleed the cooling system.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Verify that all sensors, valves, and vacuum lines are installed and connected properly. Be sure there are no loose electrical connections.
  14.  
  15. Turn the ignition on and off several times without starting the engine to pressurize the fuel system. Run the engine and check for proper operation. Check for vacuum leaks.
  16.  
  17. After the engine has warmed up, check the operation of the throttle cable and adjust it if necessary.
  18.  


NOTE
Make sure to acquire the anti-theft code from the radio and write down the frequencies for the radio-s preset buttons.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Turn off the manual shut off valve. To reduce pressure in the lines start the engine and run it until it stalls.
  4.  
  5. Disconnect the negative battery cable. Drain the cooling system.
  6.  
  7. Remove the throttle cable. Remove the cruise control cable.
  8.  
  9. Remove the intake resonator. Remove the air cleaner. Remove the water bypass hoses.
  10.  
  11. Disconnect the power brake vacuum hose and the four way joint valve.
  12.  
  13. Remove the fuel injectors. Remove the fuel feed pipe. Disconnect the fuel feed hose. Remove the air cleaner housing bracket. Remove the thermo valve bolt and intake manifold bracket bolt.
  14.  
  15. Remove the intake manifold retaining bolts. Remove the intake manifold from the engine.
  16.  

To install:


NOTE
Use new gaskets when installing the intake manifold. Use new O-rings when installing manifold sensors and components. Use new sealing washers when reconnecting the fuel lines.

  1. Clean all gasket mating surfaces.
  2.  
  3. Torque the intake manifold retaining nuts to 16 ft. lbs. (22 Nm).
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  

2001-05 2.0L Engine

NOTE
Make sure to acquire the anti-theft code from the radio and write down the frequencies for the radio-s preset buttons.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Cooling hoses from the intake manifold
     
    Vacuum hoses and electrical connectors from the manifold and throttle body
     
    Throttle cable from the throttle body
     
    Fuel rail and fuel injectors
     
    Intake manifold support brackets
     
    Intake manifold
     

  8.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    Intake manifold fasteners: 16 ft. lbs. (22 Nm)
     
    Throttle body fasteners: 16 ft. lbs. (22 Nm)
     
    Intake manifold bracket bolts: 33 ft. lbs. (44 Nm)
     

  2.  
  3. Reprogram the power window control unit as follows.
  4.  
  5. Turn the ignition switch ON. Lower the window, all the way down. Open the driver-s side door.
  6.  
  7. Turn the ignition switch OFF. Push and hold the drivers window DOWN switch. Turn the ignition switch ON. Release the driver-s window DOWN switch. This must be done within five seconds.
  8.  
  9. Repeat the above step three more times. Wait one second.
  10.  
  11. Confirm that the AUTO UP and AUTO DOWN do not work. If they work repeat the procedure, paying close attention to the five second time limit
  12.  
  13. Move the driver-s window all the way down by holding the drivers window DOWN switch to the AUTO DOWN position.
  14.  
  15. Pull up and hold the driver-s window UP switch to the AUTO UP position until the window reaches the fully closed position. Hold the switch for one second.
  16.  
  17. Confirm that the power window master switch has been reset by using the driver-s window AUTO UP and DOWN function.
  18.  
  19. If the AUTO UP and DOWN feature is still not working, repeat the complete procedure, paying close attention to the five second time limit.
  20.  

2006 Models 2.0L Engine

NOTE
Make sure to acquire the anti-theft code from the radio and write down the frequencies for the radio-s preset buttons.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure. Disconnect the negative battery cable. Drain the cooling system.
  4.  
  5. Remove the intake manifold cover. Remove the vacuum hose, breather pipe and the intake air duct.
  6.  
  7. Remove the engine wire harness connectors and the wire harness clamps from the intake manifold.
  8.  
  9. Disconnect the four fuel injector connectors, the manifold absolute pressure connector and the throttle connector.
  10.  
  11. Remove the ground cable, harness clamp bracket and the harness holder from its mounting. Remove the PCV valve hose, evaporative emission canister hose and the power brake booster vacuum hose.
  12.  
  13. Remove the water bypass hoses. Remove the quick connect fitting cover. Disconnect the fuel feed hose.
  14.  
  15. Raise and support the vehicle safely. Remove the intake manifold connector cover. Remove the intake manifold bracket. Lower the vehicle.
  16.  
  17. Remove the intake manifold retaining bolts. Remove the intake manifold from the vehicle.
  18.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:
  2.  
  3. Torque the manifold retaining bolts and nut to specification in a crisscross pattern in two or three steps, beginning with the inner bolt.
  4.  
  5. Reprogram the power window control unit as follows.
  6.  
  7. Turn the ignition switch ON. Lower the window, all the way down. Open the driver-s side door.
  8.  
  9. Turn the ignition switch OFF. Push and hold the drivers window DOWN switch. Turn the ignition switch ON. Release the driver-s window DOWN switch. This must be done within five seconds.
  10.  
  11. Repeat the above step three more times. Wait one second.
  12.  
  13. Confirm that the AUTO UP and AUTO DOWN do not work. If they work repeat the procedure, paying close attention to the five second time limit
  14.  
  15. Move the driver-s window all the way down by holding the drivers window DOWN switch to the AUTO DOWN position.
  16.  
  17. Pull up and hold the driver-s window UP switch to the AUTO UP position until the window reaches the fully closed position. Hold the switch for one second.
  18.  
  19. Confirm that the power window master switch has been reset by using the driver-s window AUTO UP and DOWN function.
  20.  
  21. If the AUTO UP and DOWN feature is still not working, repeat the complete procedure, paying close attention to the five second time limit.
  22.  

Prelude
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant into a sealable container.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Label all vacuum hoses and electrical connectors before detaching them.



    Cooling hoses from the intake manifold
     



    Vacuum hoses and electrical connectors from the manifold and throttle body
     
    Connector from the Exhaust Gas Recirculation (EGR) valve. Position the wiring harnesses out of the way.
     
    Throttle cable from the throttle body
     

  8.  
  9. Relieve the fuel pressure.
  10.  
  11. Remove or disconnect the following:
    NOTE
    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.



    Fuel rail and fuel injectors
     
    Thermostat housing from the intake manifold and the connecting pipe by pulling and twisting the housing. Discard the O-rings.
     



    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.
     

  12.  
  13. 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.
  14.  
  15. Clean any old gasket material from the cylinder head and the intake manifold. Check and clean the FIA chamber on the cylinder head.
  16.  

To install:

  1. Install or connect the following:

    New gasket
     
    Intake manifold, and support the manifold.
     
    Support bracket to the manifold. Tighten the retaining bolt to 16 ft. lbs. (22 Nm).
     

  2.  
  3. 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).
  4.  
  5. Install or connect the following:

    New gasket
     
    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).
     
    New O-ring to the coolant connecting pipe, and to the thermostat housing.
     
    Housing to the coolant pipe and the intake manifold. Tighten the mounting bolts to 16 ft. lbs. (22 Nm).
     
    Throttle cable and adjust.
     
    Fuel rail/injector assembly
     
    Fuel lines
     
    Wiring harnesses and the electrical connectors
     
    Vacuum hoses
     

  6.  
  7. Fill and bleed the air from the cooling system.
  8.  
  9. Connect the negative battery cable and enter the radio security code.
  10.  
  11. 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.
  12.  
  13. If equipped with 4WS, turn the steering wheel lock-to-lock to reset the 4WS control unit.
  14.  

S2000

NOTE
Make sure to acquire the anti-theft code from the radio and write down the frequencies for the radio-s preset buttons.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Cooling hoses from the intake manifold
     
    Vacuum hoses and electrical connectors from the manifold and throttle body
     
    Throttle cable from the throttle body
     
    Fuel rail and fuel injectors
     
    Intake manifold support brackets
     
    Intake manifold

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold and related components-S2000 with 2.0L engine

     

  8.  

To install:


NOTE
Use new gaskets when installing the intake manifold. Use new O-rings when installing manifold sensors and components. Use new sealing washers when reconnecting the fuel lines.

  1. Clean all gasket mating surfaces.
  2.  
  3. Torque the intake manifold retaining nuts to specification.
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  
  7. Reprogram the power window control unit as follows.
  8.  
  9. Turn the ignition switch ON. Lower the window, all the way down. Open the driver-s side door.
  10.  
  11. Turn the ignition switch OFF. Push and hold the drivers window DOWN switch. Turn the ignition switch ON. Release the driver-s window DOWN switch. This must be done within five seconds.
  12.  
  13. Repeat the above step three more times. Wait one second.
  14.  
  15. Confirm that the AUTO UP and AUTO DOWN do not work. If they work repeat the procedure, paying close attention to the five second time limit
  16.  
  17. Move the driver-s window all the way down by holding the drivers window DOWN switch to the AUTO DOWN position.
  18.  
  19. Pull up and hold the driver-s window UP switch to the AUTO UP position until the window reaches the fully closed position. Hold the switch for one second.
  20.  
  21. Confirm that the power window master switch has been reset by using the driver-s window AUTO UP and DOWN function.
  22.  
  23. If the AUTO UP and DOWN feature is still not working, repeat the complete procedure, paying close attention to the five second time limit.
  24.  

 
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