2003 ACCORD - Intake Manifold Removal and Installation

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1 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 (B) and breather pipe (C), then remove the intake air duct (D). 3. Remove the engine cover. 4. Remove the throttle cable (A) and cruise control actuator cable (B) by loosening the locknuts (C), then slipping the cable ends out of the accelerator linkage. Take care not to bend the cables when removing them. Always replace any kinked cable with a new one. American Honda Motor Co., Inc. Page 1 of 12

2 5. Remove the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B). 6. Remove the engine wire harness connectors and wire harness clamps from the intake manifold. Idle air control (IAC) valve connector Throttle position sensor connector Manifold absolute pressure (MAP) sensor connector 7. Remove the bolt (A) securing the harness holder, and remove the harness clamps (B). 8. Remove and plug the water bypass hoses. American Honda Motor Co., Inc. Page 2 of 12

3 9. Remove the harness clamp (A), and the harness connector (B) from the intake manifold bracket, then remove the intake manifold bracket (C). 10. Remove the vacuum hose (A/T). 11. Remove the intake manifold. American Honda Motor Co., Inc. Page 3 of 12

4 Installation ('03-05 Models) 1. Install the intake manifold (A) with a new gasket (B), and tighten the bolts/nuts in a crisscross pattern in two or three steps, beginning with the inner bolt. 2. Install the vacuum hose (A/T). 3. Install the intake manifold bracket (A), then install the harness clamp (B), and harness connector (C) to the intake manifold bracket. American Honda Motor Co., Inc. Page 4 of 12

5 4. Install the water bypass hoses. 5. Tighten the bolt (A) securing the harness holder, and install the harness clamps (B). 6. Install the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B). 7. Install the throttle cable, then adjust the cable. 8. Install the cruise control actuator cable, then adjust the cable. American Honda Motor Co., Inc. Page 5 of 12

6 9. Install the engine cover. 10. Install the intake air duct (A), then connect the intake air temperature (IAT) sensor connector (B), and install the vacuum hose (C) and breather pipe (D). 11. Clean up any spilled engine coolant. 12. After installation, check that all tubes, hoses, and connectors are installed correctly. 13. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open. Removal ('06-07 Models) American Honda Motor Co., Inc. Page 6 of 12

7 1. Remove the vacuum hose (A) and breather pipe (B), then remove the intake air duct (C). 2. Remove the engine cover. 3. Remove the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B). 4. Remove the engine wire harness connectors and wire harness clamps from the intake manifold. Throttle actuator connector Manifold absolute pressure (MAP) sensor connector 5. Remove the harness holder (A), and remove the harness clamp (B). American Honda Motor Co., Inc. Page 7 of 12

8 6. Remove and plug the water bypass hoses. 7. Remove the harness clamp (A) and the harness connector (B) from the intake manifold bracket, then remove the intake manifold bracket (C). 8. Remove the vacuum hose. A/T model: American Honda Motor Co., Inc. Page 8 of 12

9 M/T model: 9. Remove the intake manifold. Installation ('06-07 Models) 1. Install the intake manifold (A) with a new gasket (B), and tighten the bolts/nuts in a crisscross pattern in two or three steps, beginning with the inner bolt. American Honda Motor Co., Inc. Page 9 of 12

10 2. Install the vacuum hose. A/T model: M/T model: 3. Install the intake manifold bracket (A), then install the harness clamp (B), and harness connector (C) to the intake manifold bracket. American Honda Motor Co., Inc. Page 10 of 12

11 4. Install the water bypass hoses. 5. Install the harness holder (A), and install the harness clamp (B). 6. Reconnect the MAP sensor and throttle actuator connectors. 7. Install the EVAP canister hose (A) and brake booster vacuum hose (B). American Honda Motor Co., Inc. Page 11 of 12

12 8. Install the engine cover. 9. Install the intake air duct (A), then install vacuum hose (B) and breather pipe (C). 10. Clean up any spilled engine coolant. 11. After installation, check that all tubes, hoses, and connectors are installed correctly. 12. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open. American Honda Motor Co., Inc. Page 12 of 12

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