Intake Manifold: Service and Repair
Intake Manifold Removal and InstallationExploded View - K20A3 Engine:
Removal - K20A3 Engine
1. Remove the intake manifold cover.
2. Disconnect the intake air temperature (IAT) sensor connector (A), and remove the breather hose (B), then remove the air cleaner housing (C).
3. Remove the throttle cover (A). Fully open the throttle link and cruise control link by hand, then remove the throttle cable (B) and cruise control actuator cable (C) from the links. Loosen the locknuts (D), and remove the cables from the bracket.
4. Remove the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B).
5. Remove the water bypass hoses, then plug the water bypass hoses.
6. Disconnect the intake manifold runner control (IMRC) valve actuator control solenoid valve connector (A), then remove the positive crankcase ventilation (PCV) hose (B) and IMRC valve control solenoid valve mounting bolt (C).
7. Remove the front bumper.
8. Disconnect the hood switch connector (A), then remove the air conditioning (A/C) line bracket mounting bolt (B), intake air duct mounting bolt (C), and harness clamps (D).
9. Remove the upper bracket and cushion mounting bolts (A), then remove the bulkhead (B).
10. Remove the engine wire harness connectors and wire harness clamps from the intake manifold.
^ Idle air control (IAC) valve connector
^ Throttle position (TP) sensor connector
^ Manifold absolute pressure (MAP) sensor connector
^ Evaporative emission (EVAP) canister purge valve connector
^ Intake manifold runner control (IMRC) valve position sensor connector
11. Remove the intake manifold.
Installation - K20A3 Engine
1. Install the intake manifold (A), and tighten the bolts/nuts in a crisscross pattern in two or three steps, beginning with the inner bolt. Use new O-rings (B).
2. Install the bulkhead (A), then install the upper bracket and cushion mounting bolts (B).
3. Connect the hood switch connector (A), then install the A/C line bracket mounting bolt (B), intake air duct mounting bolt (C) and harness clamps (D).
4. Install the front bumper.
5. Connect the IMRC valve actuator control solenoid valve connector (A), then install the PCV hose (B) and IMRC valve actuator control solenoid valve mounting bolt (C).
6. Install the water bypass hoses.
7. Install the EVAP canister hose (A) and brake booster vacuum hose (B).
8. Install the throttle cable, then adjust it.
9. Install the cruise control actuator cable, then adjust it.
10. Install the air cleaner housing (A) and connect the IAT sensor connector (B).
11. Install the breather hose (C).
12. Install the intake manifold cover.
13. After installation, check that all tubes, hoses, and connectors are installed correctly.
14. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
15. Clean up any spilled engine coolant.
Exploded View- K20A2, K20Z1 Engines:
Removal - K20A2, K20Z1 Engines
1. Relieve fuel pressure.
2. Remove the intake manifold cover.
3. Remove the EVAP canister hose (A), brake booster vacuum hose (B), and vacuum hoses (C).
4. Disconnect the IAT sensor connector (A), and remove the breather hose (B), then remove the air cleaner housing (C).
5. Fully open the throttle link and cruise control link by hand, then remove the throttle cable (A) and cruise control actuator cable (B) from the links. Loosen the locknuts (C), and remove the cables from the bracket.
6. Remove the water bypass hoses, then plug the water bypass hoses.
7. Remove the fuel feed hose.
8. Remove the PCV hose (A), harness holder mounting bolt (B), and harness clamp mounting bolt (C).
9. Remove the engine wire harness connectors and wire harness clamps from the intake manifold.
^ Four injector connectors
^ IAC valve connector
^ TP sensor connector
^ MAP sensor connector
^ EVAP canister purge valve connector
10. Remove the two bolts securing the intake manifold and brackets.
11. Remove all the intake manifold mounting bolts/ nuts (A).
12. Remove the two stud bolts (B), then remove the intake manifold (C).
Installation - K20A2, K20Z1 Engines
1. Install the intake manifold (A) with a new gasket (B), then tighten the two stud bolts (C).
2. Tighten all intake manifold mounting bolts/nuts (D) in a crisscross pattern in two or three steps, beginning with the inner bolt.
3. Tighten the two bolts securing the intake manifold.
4. Install the PCV hose (A), harness holder mounting bolt (B), and harness clamp mounting bolt (C).
5. Install the fuel feed hose.
6. Install the water bypass hoses.
7. Install the throttle cable, then adjust it.
8. Install the cruise control actuator cable, then adjust it.
9. Install the air cleaner housing (A) and connect the IAT sensor connector (B).
10. install the breather hose (C).
11. Install the EVAP canister hose (A), brake booster vacuum hose (B), and vacuum hoses (C).
12. Install the intake manifold cover.
13. After installation, check that all tubes, hoses, and connectors are installed correctly.
14. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so that the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
15. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
16. Clean up any spilled engine coolant.