K20A3 Engine

Intake Manifold Removal and Installation

Intake Manifold - K20A3 Engine:

Removal





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 tuning (IMT) (intake manifold runner control (IMRC)) valve actuator control solenoid valve connector (A), then remove the positive crankcase ventilation (PCV) hose (B) and IMT (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 tuning (IMT) (intake manifold runner control (IMRC)) valve position sensor connector





11. Remove the intake manifold.

Installation





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 NC line bracket mounting bolt (B), intake air duct mounting bolt (C) and harness clamps (D).
4. Install the front bumper.





5. Connect the IMT (IMRC) valve actuator control solenoid valve connector (A), then install the PCV hose (B) and IMT (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.