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Honda Civic Service Manual: Intake Manifold Removal and Installation (R18Z1)

Honda Civic Service Manual / Powertrain / Engine / Intake and Forced Induction / Intake Manifold Removal and Installation (R18Z1)

View

1. Intake Manifold Exploded View

Exploded View


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Removal

NOTE: Refer to the Exploded View if needed during this procedure.


1. Wiper Arm Assembly


NOTE: Set the wiper arms to the auto-stop position before removal.


1.

Remove the cowl top wiper covers (A).


2.

Remove the wiper arms (B).


2. Both Side Cowl Covers


1.

Remove the side cowl cover (A).


2.

The left side is shown; repeat on the right side.


3. Center Cowl Cover


1.

Remove the center cowl cover (A).


2.

Disconnect the windshield washer tube (B).


3.

If necessary, remove the hood rear seal (C).


4. Under Cowl Panel

1.

Remove the under cowl panel (A).


5. Fuel Filler Cap

1.

Remove the fuel fill cap to relieve the pressure in the fuel tank.


6. HDS DLC - Connection


NOTE: For specific operations, refer to the user's manual that came with the Honda Diagnostic System (HDS). Make sure the HDS is loaded with the latest software.


1.

Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.


2.

Turn the ignition switch to ON (II).


3.

Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.


7. Fuel Pump Off

1.

Turn the ignition switch to ON (II).


2.

From the INSPECTION MENU of the HDS, select Fuel Pump OFF, then start the engine, and let it idle until it stalls.


NOTE:

Do not allow the engine to idle above 1,000 rpm or the ECM/PCM will continue to operate the fuel pump.

Pending or Confirmed DTC may be set during this procedure. Check for DTCs, and clear them as needed.


3.

Turn the ignition switch to LOCK (0).


8. Battery Terminal - Disconnection


1.

Make sure the ignition switch is in LOCK (0).


2.

Disconnect and isolate the negative cable and battery sensor (A) from the battery.


NOTE: Always disconnect the negative side first.


3.

Disconnect the positive cable (B) from the battery.


9. Fuel Pressure - Relieving


1.

Remove the quick-connect fitting cover (A).


2.

Check the fuel quick-connect fitting for dirt, and clean it if needed.


3.

Place a rag or shop towel over the quick-connect fitting (A).


4.

Disconnect the quick-connect fitting: Hold the connector (A) with one hand, and squeeze the retainer tabs (B) with the other hand to release them from the locking tabs (C). Pull the connector off.


NOTE:

Be careful not to damage the line (D) or other parts.

Do not use tools.

If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily.

Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.


10. Air Cleaner


1.

Disconnect the intake air duct (A).


2.

Remove the air cleaner (B).


3.

Remove the harness clamp (C).


11. Intake Air Duct

1.

Remove the intake air duct.


12. Throttle Body - Removal

1.

Remove the throttle body without disconnecting the hoses.


13. Intake Manifold Assembly

1.

Disconnect the EVAP canister hose (A), the brake booster vacuum hose (B), and the PCV hose (C).


2.

Remove the heater hose clamp bracket.


3.

Remove the intake manifold bracket.



4.

Disconnect the connectors (A).


5.

Remove the harness clamps.


6.

Remove the intake manifold assembly.


Installation

NOTE: Refer to the Exploded View if needed during this procedure.


1. Intake Manifold Assembly

mm


1.

Install the intake manifold assembly (A) with new gaskets (B).


2.

Tighten the bolts/nuts in a crisscross pattern in three steps, beginning with the inner bolt.



3.

Install the connectors (A).


4.

Connect the harness clamps.


5.

Install the intake manifold bracket.


6.

Install the heater hose clamp bracket.


7.

Connect the EVAP canister hose (A), the brake booster vacuum hose (B), and the PCV hose (C).


2. Throttle Body - Installation

mm

1.

Install the throttle body (A) with new O-ring (B).


3. Intake Air Duct

1.

Install the intake air duct.


4. Air Cleaner


1.

Install the harness clamp (A).


2.

Install the air cleaner (B).


3.

Connect the intake air duct (C).


5. Injector Base Fuel Feed Hose - Reconnection

1.

Connect the fuel feed hose.


6. Under Cowl Panel

22mm)2222

1.

Install the under cowl panel (A).


7. Center Cowl Cover


1.

If necessary, install the hood rear seal (A).


2.

Connect the windshield washer tube (B).


3.

Install the center cowl cover (C).


8. Both Side Cowl Covers


1.

Install the side cowl cover (A).


2.

The left side is shown; repeat on the right side.


9. Wiper Arm Assembly

1.122


NOTE: Set the wiper arms to the auto-stop position before installation.


1.

Install the wiper arms (A).


2.

Install the cowl top wiper covers (B).


10. Fuel Filler Cap

1.

Install the fuel fill cap.


11. Battery Terminal - Reconnection


NOTE: If the battery performs abnormally, test the battery.


1.

Clean the battery terminals.


2.

Connect the positive cable (A) to the battery.


NOTE: Always connect the positive side first.


3.

Connect the negative cable and battery sensor (B) to the battery.


4.

Apply multipurpose grease to the terminals to prevent corrosion.


12. HDS DLC - Connection


1.

Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.


2.

Turn the ignition switch to ON (II).


3.

Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.


13. Fuel Pump On

1.

From the INSPECTION MENU of the HDS, select Fuel Pump ON.


NOTE: Pending or Confirmed DTC may be set during this procedure. Check for DTCs, and clear them as needed.


2.

Turn the ignition switch to LOCK (0).


14. Fuel Line Leak Check

1.

Turn the ignition switch to ON (II) (but do not operate the starter motor). The fuel pump runs for about 2 seconds, and fuel pressure rises. Repeat this two or three times, then make sure there are no fuel leaks.


15. Tubes, Hoses, and Connectors After Installation Check

1.

After installation, check that all tubes, hoses, and connectors are installed correctly.


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