Automotive Manual PDF

Preparation for Installation
1. Make sure that there are no metal chips or other debris inside the manifold. Check that all bolts will run freely into any tapped holes.
2. Note that while this manifold makes provision for all vacuum lines and other brackets or parts that attached to the stock manifold, the vacuum ports originally on the front side of the manifold have been moved to the back for a cleaner appearance. This will require the use of longer vacuum hoses in some cases.
3. Disconnect battery and drain coolant.
4. Mark and identify all hoses and valves.
5. Check the condition of all hoses, gaskets and o-rings. Replace as needed. Use a new intake gasket. Honda #17105-P72-004.
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This kit is intended for use in applications where a remote mounted idle air control motor is necessary, and an ecu with the ability to control a Honda idle air control motor is being used. These instructions will specifically go over the ecu setup for an AEM EMS, though it can also be used with other systems such as Motec or Haltech.
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Relieving fuel pressure
a) Remove the fuel fill cap.
b) On models equipped with a 6mm service bolt. (illustrated below) If your vehicle is not equipped with a 6mm service bolt, then proceed to step c.
i) Use a box end wrench on the 6mm service bolt on top of the fuel filter or fuel rail, while holding the special banjo bolt with another wrench.
ii) Place a rag or shop towel over the 6mm service bolt.
iii) Slowly loosen the 6mm service bolt one complete turn.
iv) Leave service bolt loose until all pressure has been relieved.
v) Tighten service bolt to 10 lbf-ft.
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Tools Recommended: metric deep socket set, metric & American open end wrench set, 9/64th Allen wrench, Teflon tape, wire cutters, terminal crimpers.
Follow the included diagram exactly. This product uses two different but visually similar threads. 1/8” NPT and 1/8” BSPT may appear to be the same thread, but they are not. Do not assemble any portion of this kit in any way other than described. Doing so will result in stripped threads and oil leaks.
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PREPARATION
1. Remove the EVAP hose, brake booster hose, PCV hose, vacuum hose, water bypass hoses, throttle cable, fuel lines, fuel injector connectors, IAC valve connector, TP sensor connector, MAP sensor connector, and EVAP canister purge valve connector from your current intake manifold and throttle body setup.
2. Remove the throttle body.
3. Remove the intake manifold brackets, intake manifold, and intake manifold gasket.
If adapting an Accord Euro R or 06 Civic Si intake manifold onto an 02-06 RSX/ITR or 02-05 Civic Si/CTR style head, continue to follow the remaining “PREPARATION” steps, otherwise skip to “INSTALLATION”
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Removal of the Stock Air Intake System
a) Loosen the clamp around the throttle body using a 5.5mm socket or screwdriver. Pull the Intake Air Temperature (IAT) sensor out of the intake tube by loosening the spring loaded clamp.
b) Unplug the breather tube from the fitting underneath the intake manifold.
c) Remove the air box mounting bolt shown in the picture.
d) Remove the other air box mounting shown in the picture.
e) Carefully remove the air box assembly from the engine bay.
f) Remove the two fasteners holding the plastic cover in front of the battery.
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STEP I ASSEMBLY INSTRUCTIONS – Fuel Pump / Carburetor / Manifold
A) Install fuel pump on carburetor, using shortest fuel line hose (1 ū” long) and two small diameter clamps. Ensure that you connect the correct nipple from the fuel pump to the carburetor. (Refer to Fig. 3)
B) Install carburetor and fuel pump assembly on the intake manifold, along with gaskets, insulation block, lock washers and nuts supplied in kit. (Refer to Fig. 2) Tighten nuts to 8 – 12 foot lbs. torque.
C) Attach one end of 7″ fuel line to the pulse tube on the intake manifold. Slide two small diameter clamps over the fuel line and then attach the other end of the line to the crankcase fitting on fuel pump. (Refer to Fig 3.) Position clamps at each end of hose and tighten securely. Proceed to STEP II.
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1. Start by disconnecting the wire harness from the MAF sensor as shown.
2. Remove the cover from the intake manifold by lifting it up and then pulling it out as shown.
3. Unplug the vent air tube from the stock air silencer as shown.
4. Remove the clip holding the radiator hose to the stock air tube as shown.
5. Loosen the hose clamp on the stock air tube at the MAF meter and the throttle body and remove the stock air tube as shown.
6. Remove the cover of the stock air box as shown and set aside.
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Pump mounting
We have found the best location if using a tank in the bed is in this location. Drill 4 holes
Remove Intake
On LMM LBZ
Loosen all bolts and nuts labeled with red arrows
On LLY
Loosen 6, 12mm bolts/nuts on the intake manifold. Remove the intake manifold. (Note: it will not be easy to get at all the bolts and remove the manifold, but it can be done just moving the cables out of the way) Be careful not to lose the 2 EGR gaskets and 1 intake manifold gasket.
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1. Disconnect the negative battery cable! Remove the plastic wing nut on the air intake hat behind the throttlebody. Loosen the hose clamp that secures the flexible intake tube to the throttle body hat. Disconnect the crankcase breather hose. Roll the air intake hat towards the front of the vehicle to remove it, and set it aside.
2. A.) Remove the three bolts that secure the throttlebody to the intake manifold. B.) Remove the bolt that secures the throttle cable bracket to the throttlebody. C.) Lift up the tabs, and disconnect the two wiring harnesses of the drivers side of the throttlebody. Lift the throttlebody off of the intake manifold and set it to the side.
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