2003 RSX - Intake Manifold Removal and Installation

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Shanna Miller
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2 2003 RSX - Intake Manifold Removal and Installation Exploded 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.

3 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.

4 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

5 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).

6 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.

7 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. A

8 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.

9 American Honda Motor Co., Inc. Page 8 of 8

10 2003 RSX - Starter Removal and Installation Removal 1. Make sure you have the anti-theft codes for the radio, then write down the customer's radio station presets. 2. Disconnect the negative cable from the battery first, then disconnect the positive cable. 3. Disconnect the knock sensor connector. 4. K20A3 engine: Disconnect the bolt securing the harness bracket. 5. K20A2, K20Z1 engines: Remove the front subframe damper. 6. K20A2, K20Z1 engines: Remove the bolt (A) securing the harness bracket, then remove the intake manifold brackets (B).

11 7. Disconnect the starter cable (A) from the B terminal on the solenoid, then disconnect the BLK/WHT wire (B) from the S terminal. 8. Remove the two bolts holding the starter, then remove the starter. K20A3 engine K20A2, K20Z1 engines

12 Installation 1. Install the two bolts holding the starter. 2. Connect the starter cable (A) from the B terminal on the solenoid, then connect the BLK/WHT wire (B) from the S terminal. Make sure the crimped side of the ring terminal is facing out. K20A3 engine K20A2, K20Z1 engines 3. K20A2, K20Z1 engines: Install the bolt (A) securing the harness bracket, then Install the intake manifold brackets (B).

13 4. K20A2, K20Z1 engines: Install the front subframe damper. 5. K20A3 engine: Connect the bolt securing the harness bracket. 6. Connect the knock sensor connector. 7. Connect the positive cable to the battery first, then connect the negative cable. 8. Start the engine to make sure the starter operates properly. 9. Enter the anti-theft codes for the radio, then enter the customer's radio station presets. 10. Set the clock models: Do the engine control module (ECM) /powertrain control module (PCM) idle learn procedure. 12. Do the power window control unit reset procedure.

15 2003 RSX - Starter Solenoid Test K20A2, K20Z1 Engines 1. Make sure you have the anti-theft codes for the radio, then write down the customer's radio station presets. 2. Disconnect the nagative cable from the battery first, then disconnect the positive cable. 3. Disconnect the S and M connectors from the starter solenoid. 4. Check the hold-in coil for continuity between the S terminal and the armature housing (ground). There should be continuity. If there is continuity, go to step 5. If there is no continuity, replace the solenoid. 5. Check the pull-in coil for continuity between the S terminal and M terminal. There should be continuity. If there is continuity, the solenoid is OK. If there is no continuity, replace the solenoid. 6. Connect the positive cable to the battery first, and then the negative cable. 7. Enter the anti-theft codes for the radio, then enter the customer's radio station presets. 8. Set the clock. 9. K20A2 engine: Do the engine control module (ECM)/powertrain control module (PCM) idle learn procedure models models 10. Do the power window control unit reset procedure.

2003 ACCORD - Intake Manifold Removal and Installation

2003 ACCORD - Intake Manifold Removal and Installation Exploded View '06-07 Models Removal ('03-05 Models) 1. Disconnect the intake air temperature (IAT) sensor connector (A). 2. Remove the vacuum hose