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2008 Honda CR-V

Powertrain Diagnostics & Repair / Engine / Mechanical / INTAKE MANIFOLD AND EXHAUST
SYSTEM

Intake Manifold Removal and Installation

Exploded View
Fig. 1: Exploded View Of Intake Manifold With Torque Specifications

Removal
1. Remove the hood support rod, then use it as shown to prop the hood in the wide-open position.

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Fig. 2: Identifying Hood Support Rod

2. Remove the bulkhead cover (see FRONT BULKHEAD COVER REPLACEMENT

).
3. Disconnect the fan motor connectors (A) and the hood switch connector (B), then remove the harness clips (C).

Fig. 3: Identifying Fan Motor Connectors, Hood Switch Connector And Harness Clips

4. Remove the radiator upper brackets (A), then remove the front bulkhead (B).

Fig. 4: Identifying Radiator Upper Brackets And Front Bulkhead

5. Remove the intake manifold cover.

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Fig. 5: Identifying Intake Manifold Cover

6. Disconnect the vacuum hose (A) and breather pipe (B), then remove the intake air duct (C).

Fig. 6: Identifying Vacuum Hose, Breather Pipe And Intake Air Duct

7. Remove the following engine wire harness connectors and wire harness clamps from the intake manifold:
Manifold absolute pressure (MAP) sensor connector
Throttle actuator connector

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

Fig. 7: Identifying Evaporative Emission (EVAP) Canister Hose And Brake Booster Vacuum Hose

9. Remove the harness bracket mounting bolts.

10. Disconnect the water bypass hoses, then plug the water bypass hoses.

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Fig. 8: Identifying Water Bypass Hoses And Water Bypass Hoses

11. Raise the vehicle on the lift.

12. Remove the splash shield (see FRONT SPLASH SHIELD REPLACEMENT
).
13. Remove the connector (A), then remove the intake manifold bracket (B).

Fig. 9: Identifying Connector And Intake Manifold Bracket

14. Lower the vehicle on the lift.

15. Remove the intake manifold.

Fig. 10: Identifying Intake Manifold

Installation
1. Install the intake manifold (A) with a new gasket (B), and tighten the bolts and nuts in a crisscross pattern in three steps, beginning
with the inner bolt.

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Fig. 11: Identifying Intake Manifold And Gasket With Torque Specifications

2. Raise the vehicle on the lift.

3. Install the intake manifold bracket (A), then install the connector (B).

Fig. 12: Identifying Intake Manifold Bracket And Connector With Torque Specifications

4. Install the splash shield (see FRONT SPLASH SHIELD REPLACEMENT

).
5. Lower the vehicle on the lift.
6. Install the water bypass hoses.

Fig. 13: Identifying Water Bypass Hoses

7. Install the EVAP canister hose (A) and the brake booster vacuum hose (B).

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Fig. 14: Identifying EVAP Canister Hose And Brake Booster Vacuum Hose With Torque Specification

8. Install the harness bracket mounting bolts.

9. Connect the engine wire harness connectors, and install the wire harness clamps to the intake manifold.
MAP sensor connector
Throttle actuator connector

10. Install the intake air duct (A), then install the vacuum hose (B) and the breather pipe (C).

Fig. 15: Identifying Intake Air Duct, Vacuum Hose And Breather Pipe

11. Install the intake manifold cover, 6x1.0 mm

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Fig. 16: Identifying Intake Manifold Cover With Torque Specifications

12. Install the front bulkhead (A), then install the radiator upper brackets (B).

Fig. 17: Identifying Front Bulkhead And Radiator Upper Brackets With Torque Specifications

13. Apply body paint to the bulkhead mounting bolts.

14. Connect the fan motor connectors (A) and the hood switch connector (B), then install the harness clips (C).

Fig. 18: Identifying Fan Motor Connectors, Hood Switch Connector And Harness Clips

15. Install the bulkhead cover (see FRONT BULKHEAD COVER REPLACEMENT
).

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16. Clean up any spilled engine coolant.
17. After installation, check that all tubes, hoses, and connectors are installed correctly.
18. Refill the radiator with engine coolant, and bleed the air from the cooling system (see COOLANT CHECK
).

Exhaust Manifold Removal and Installation

1. Disconnect the air fuel ratio (A/F) sensor connector and secondary heated oxygen sensor (secondary HO2S) connector, then
remove the three way catalytic converter (TWC) (see step 24 under ENGINE REMOVAL
).
2. Remove the under-cowl cover (see COWL COVER REPLACEMENT
), then remove the strut brace (see TAILGATE SUPPORT
STRUT REPLACEMENT
).
3. Remove the rocker arm oil control solenoid (see VTC OIL CONTROL SOLENOID VALVE REMOVAL/TEST/INSTALLATION
).
Remove the cover and exhaust manifold bracket, then remove the exhaust manifold.

Fig. 19: Identifying Exhaust Manifold Components With Torque Specifications

4. Install the exhaust manifold, and tighten the bolts and nuts in a crisscross pattern in three steps, beginning with the inner nut.
5. Install the other parts in the reverse order of removal.

Exhaust Pipe and Muffler Replacement

NOTE: Use new gaskets and self-locking nuts when reassembling.

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Fig. 20: Identifying Exhaust Pipe And Muffler Components With Torque Specifications

Created/Modified Date: 2/16/2012 7:40:33 AM

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