Intake Manifold Removal and Installation

Exploded View - K24A1, K20A4 (KE, KG, KS models) Engines






 

Removal - K24A1, K20A4 (KE, KG, KS models) Engines


1.Remove the intake manifold cover.

 

2.Disconnect the intake air temperature (IAT)
sensor 2 connector (A), remove the breather hose (B), and intake air bypass control thermal valve tube (C), then remove the air cleaner housing (D).

 

3.Remove the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B).

 

4.Remove the water bypass hoses, then plug the water bypass hoses.

 

5.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).

 

6.Remove the bolt (A) securing the battery clamp, then remove the bulkhead cover (B).

 

7.Remove the harness clamps.

 

8.Remove the intake air duct mounting bolts (A) and upper bracket and cushion (B), then remove the bulkhead (C).

 

9.Remove the engine wire harness connectors and wire harness clamps from the intake manifold.

  • Throttle actuator connector
  • Manifold Absolute Pressure (MAP) sensor connector
  • Evaporative Emission (EVAP) canister purge valve connector

 

10.Remove the intake manifold.

 

Installation - K24A1, K20A4 (KE, KG, KS models) Engines


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. Using the new
O-rings (B).

 

2.Install the engine wire harness connectors and wire harness clamp to the intake manifold.

 

3.Install the bulkhead (A), then install the upper bracket and cushion (B), and intake air duct mounting bolts (C). Apply body paint to the bulkhead mounting bolts.

 

4.Connect the harness clamps.

 

5.Install the bulkhead cover (A), then install the battery clamp bolt (B).

 

6.Connect the intake manifold runner control (IMRC) valve actuator control solenoid valve connector (A), then install the positive crankcase ventilation (PCV) hose (B) and IMRC valve actuator control solenoid valve mounting bolt (C).

 

7.Install the water bypass hoses.

 

8.Install the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B).

 

9.Install the air cleaner housing (A) and connect the intake air temperature (IAT) sensor 2 connector (B).

 

10.Install the breather hose (C) and intake air bypass control thermal valve tube (D).

11.Install the intake manifold cover.

 

12.Clean up any spilled engine coolant.

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.