Acura GSR Whirlwind Intake Manifold Instructions
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.
Removal
1. Relieve the fuel pressure in the system by loosening the banjo bolt on the top of the fuel filter. Disconnect the fuel line from the fuel rail. It is a good idea to replace the washers. Disconnect the fuel harness holder and unbolt. Disconnect the hoses from the fuel pressure regulator (FPR).
2. Disconnect intake hose/pipe from throttle body. Disconnect all hoses leading to the throttle body and intake manifold. Disconnect throttle cable bracket on manifold and throttle cable from throttle body. Disconnect the cables to the the throttle position sensor (TPS) and the map sensor on the throttle body.
3. Unbolt two lower intake manifold bolts that secure manifold to engine block. This bracket willl still be used to accommodate the heater bypass pipe. Unbolt manifold from engine block. Remove manifold, throttle body, and fuel rail as one unit.
4. Remove the intake air bypass (IAB) vacuum tank, check valve and control solenoid unit. Due to the different design of your new manifold, these parts will no longer be used. Do not remove the FPR hose. This hose will be used in the re-installation process.
5. Unbolt throttle body from manifold. Inspect gasket and replace if needed. Unscrew throttle body studs from flange of manifold. Remove fuel rail assembly from manifold.
6. From original manifold, unbolt and remove idle air control valve (IAC), intake air temperature valve (IAT), and o-rings. Replace o-rings if needed. Remove fuel rail studs from original manifold.
Assembly
1. Screw throttle body studs and fuel rail studs removed from original manifold into the new Power+Plus Manifold.
2. Bolt throttle body to new manifold. When positioning throttle body gasket, the U-shaped portion is in top left corner of flange.
3. Bolt idle air control valve, intake air temperature valve with o-rings to new manifold. Install fuel rail, making sure o-rings are positioned correctly to prevent fuel leakage.
4. Position new manifold assembly with throttle body and fuel rail back on the cylinder head over the studs, making sure new intake gasket is properly positioned. Connect the EVAP purge control solenoid valve. Due to the new intake manifold design, there is no mounting location for for the EVAP purge control solenoid valve. It can be zip-tied to a secure location. For 1994-’95 vehicles, one hose end will plug into the charcoal canister and the other hose end will plug into the small vacuum fitting located onthe rear of the new intake manifold. For 1996-01 vehicles. see notes below.
5. Bolt on the fuel injector harness holder and hoses, connecting the harness to the injectors. Connect TPS, map sensor, and fuel line. The FPR hose will connect to the small vacuum fitting that was originally on the front of the manifold but is now on the back. Tighten banjo bolt on top of fuel filter.
6. Use the new supplied throttle cable bracket to hook up stock throttle cable to the throttle body.
7. Connect battery and replace coolant. Cap off any unused vacuum tubes with vacuum caps.
8. Start engine, check for leaks. After engine is brought to operating temperature, shut it off and check that all nuts and bolts are tight. Retighten manifold bolts after 500 miles.
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