Home ReviewsRefund
Home/Acura/RSX/Acura RSX I (2001-2004)/Repair manual/Exhaust/Intake Manifold and Exhaust System
Contents Wiring diagrams Section: Exhaust All sections

Intake Manifold and Exhaust System Acura RSX I

Exhaust 36 illustrations ~1377 words

Scheme 1

Scheme 1: Exploded View - K20A3 Engine
Scheme 1: Exploded View - K20A3 Engine

Scheme 2

Scheme 2: Removal - K20A3 Engine
Scheme 2: Removal - K20A3 Engine

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10
  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.
  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 (see «FRONT BUMPER REMOVAL/INSTALLATION»(/acura/rsx/i-2001-2004/remont/exterior-body-panels/#bumpers) ).
  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
  11. Remove the intake manifold.

Scheme 11

Scheme 11: Installation - K20A3 Engine
Scheme 11: Installation - K20A3 Engine

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18
  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).
  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 (see «FRONT BUMPER REMOVAL/INSTALLATION»(/acura/rsx/i-2001-2004/remont/exterior-body-panels/#bumpers) ).
  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 (see «THROTTLE CABLE REMOVAL/INSTALLATION»(/acura/rsx/i-2001-2004/remont/testing-diagnostics/#intake-air-system) ), then adjust it (see «THROTTLE CABLE ADJUSTMENT»(/acura/rsx/i-2001-2004/remont/testing-diagnostics/#intake-air-system) ).
  9. Install the cruise control actuator cable, then adjust it (see «CRUISE CONTROL ACTUATOR CABLE ADJUSTMENT»(/acura/rsx/i-2001-2004/remont/cruise-control-systems/#cruise-control) ).
  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 (see step 7 on «COOLANT REPLACEMENT»(/acura/rsx/i-2001-2004/remont/cooling-system-mechanical/#cooling-system) ).
  15. Clean up any spilled engine coolant.

Scheme 19

Scheme 19: Exploded View - K20A2, K20Z1 Engines
Scheme 19: Exploded View - K20A2, K20Z1 Engines

Scheme 20

Scheme 20: Removal - K20A2, K20Z1 Engines
Scheme 20: Removal - K20A2, K20Z1 Engines

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27
  1. Relieve fuel pressure (see «FUEL PRESSURE RELIEVING»(/acura/rsx/i-2001-2004/remont/fuel-system/#fuel-supply-system__fuel-pressure-relieving) ).
  2. Remove the intake manifold cover.
  3. Remove the EVAP canister hose (A), brake booster vacuum hose (B), and vacuum hoses (C).
  4. Disconnect the IAT sensor connector (A), and remove the breather hose (B), then remove the air cleaner housing (C).
  5. Fully open the throttle link and cruise control link by hand, then remove the throttle cable (A) and cruise control actuator cable (B) from the links. Loosen the locknuts (C), and remove the cables from the bracket.
  6. Remove the water bypass hoses, then plug the water bypass hoses.
  7. Remove the fuel feed line (see «FUEL LINE/QUICK-CONNECT FITTING REMOVAL»(/acura/rsx/i-2001-2004/remont/fuel-system/#fuel-supply-system__fuel-linequick-connect-fitting-removal) ).
  8. Remove the PCV hose (A), harness holder mounting bolt (B), and harness clamp mounting bolt (C).
  9. Remove the engine wire harness connectors and wire harness clamps from the intake manifold. Four injector connectors IAC valve connector TP sensor connector MAP sensor connector EVAP canister purge valve connector
  10. Remove the two bolts securing the intake manifold and brackets.
  11. Remove all the intake manifold mounting bolts/nuts (A).
  12. Remove the two stud bolts (B), then remove the intake manifold (C).

Scheme 28

Scheme 28: Installation - K20A2, K20Z1 Engines
Scheme 28: Installation - K20A2, K20Z1 Engines

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30

Scheme 31

Scheme 31
Scheme 31

Scheme 32

Scheme 32
Scheme 32

Scheme 33

Scheme 33
Scheme 33

Scheme 34

Scheme 34
Scheme 34
  1. Install the intake manifold (A) with a new gasket (B), then tighten the two stud bolts (C).
  2. Tighten all intake manifold mounting bolts/nuts (D) in a crisscross pattern in two or three steps, beginning with the inner bolt.
  3. Tighten the two bolts securing the intake manifold and brackets.
  4. Install the PCV hose (A), harness holder mounting bolt (B), and harness clamp mounting bolt (C).
  5. Install the fuel feed line (see «FUEL LINE/QUICK-CONNECT FITTING INSTALLATION»(/acura/rsx/i-2001-2004/remont/fuel-system/#fuel-supply-system__fuel-linequick-connect-fitting-installation) ).
  6. Install the water bypass hoses.
  7. Install the throttle cable (see «THROTTLE CABLE REMOVAL/INSTALLATION»(/acura/rsx/i-2001-2004/remont/testing-diagnostics/#intake-air-system) ), then adjust it (see «THROTTLE CABLE ADJUSTMENT»(/acura/rsx/i-2001-2004/remont/testing-diagnostics/#intake-air-system) ).
  8. Install the cruise control actuator cable, then adjust it (see «CRUISE CONTROL ACTUATOR CABLE ADJUSTMENT»(/acura/rsx/i-2001-2004/remont/cruise-control-systems/#cruise-control) ).
  9. Install the air cleaner housing (A) and connect the IAT sensor connector (B).
  10. Install the breather hose (C).
  11. Install the EVAP canister hose (A), brake booster vacuum hose (B), and vacuum hoses (C).
  12. Install the intake manifold cover.
  13. After installation, check that all tubes, hoses, and connectors are installed correctly.
  14. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so that the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
  15. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open (see step 7 on «COOLANT REPLACEMENT»(/acura/rsx/i-2001-2004/remont/cooling-system-mechanical/#cooling-system) ).
  16. Clean up any spilled engine coolant.

Scheme 35

Scheme 35: Exhaust Manifold Removal and Installation
Scheme 35: Exhaust Manifold Removal and Installation
  1. Remove the rocker arm oil control solenoid (VTEC solenoid valve) (see «ROCKER ARM OIL CONTROL SOLENOID (VTEC SOLENOID VALVE) ASSEMBLY REMOVAL/INSTALLATION»(/acura/rsx/i-2001-2004/remont/testing-diagnostics/#vtecvtc) ).
  2. Remove the intermediate shaft cover (see step 36 on «TRANSMISSION REMOVAL»(/acura/rsx/i-2001-2004/remont/automatic-trans/#automatic-transmission) ).
  3. Remove the cover and exhaust manifold bracket, then remove the exhaust manifold. NOTE: With a 2005-2006 models, do not reuse the flexible joint gasket, when removing it. Check the flexible joint gasket for damage. If the flexible joint gasket is damaged, replace the flexible joint gasket (see «FLEXIBLE JOINT GASKET REPLACEMENT»(/acura/rsx/i-2001-2004/remont/exhaust/#intake-manifold-and-exhaust-system) ).
  4. Install the exhaust manifold and tighten the bolts/nuts in a crisscross pattern in two or three steps, beginning with the inner bolt.
  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. With a 2005-2006 models, do not reuse the flexible joint gasket, when removing it. Check the flexible joint gasket for damage. If the flexible joint gasket is damaged, replace the flexible joint gasket (see FLEXIBLE JOINT GASKET REPLACEMENT ).

Scheme 36

Scheme 36: 2005-2006 Models
Scheme 36: 2005-2006 Models
  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) assembly (see step 28 on «ENGINE INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#engine-removal-and-installation) ).
  2. Check the flexible joint gasket for damage. If the flexible joint gasket is damaged, remove the flexible joint gasket.
  3. Using the wooden block (A) and plastic mallet (B), gently tap in the new flexible joint gasket until the gasket bottoms on the exhaust manifold flange. NOTE: When installing the flexible joint gasket, flat side is facing the exhaust manifold flange. Do not reuse the flexible joint gasket, when removing it. Do not install the TWC to the exhaust manifold, before flexible joint gasket is seated properly. Take care not to damage the sliding surface of the flexible joint gasket.
  4. Using the 0.05 mm (0.002 in.) feeler gauge, check the flexible joint gasket properly seated on the exhaust manifold flange.
  5. Visually check the flexible joint gasket for damage, if a damaged or loosen string is detected, replace the flexible joint gasket.
  6. Install the TWC assembly, then connect the A/F sensor connector and secondary HO2S connector (see step 20 on «ENGINE INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#engine-removal-and-installation) ).