KMS intake manifold DIY
Thread Starter
Joined: Jun 2002
Posts: 3,242
Likes: 0
From: so cal djmota=oscar
Rep Power: 323 
KMS intake manifold DIY Here it is as promised.
Ok here is the list of stuff you’ll need on hand before you start the install.
Jack and 2 jack stands
2 6x25mm bolts 1.25 thread pitch
2 6mm wave or lock washers
18 6mm flat washers.
2 8mm or half inch bolts to use as plugs 2or3 inches long
1 8x45mm bolt with a 1.25 thread pitch and a wave washer for the same.
1 tube of loctite thread locker med. Strength
1 tube of hondabond
3 small hose clamps
allen socket to fit the new Throttle body bolts
12mm wrench
13mm wrench
10mm socket
12mm short socket ¼ drive
and of course the ¼ drive socket wrench
pliers
and tools to take off your intake.
Jack up the front of the car and support with jack stands (taking off the left wheel helps but is not nec.)
Take off the air intake of your choice, and throw it in the trunk.
Unplug all the wire plugs and label the with masking tape so you don’t forget where they go..injector plugs also.
Label the top coolant hose going to the pass side of the TB (Throttle Body) Unplug both of them and replug them with the 2 bolts.
Unbolt the bracket on the pass side of the IM (Intake Manifold) remove the plactic clip holding the 2 big hoses from the bracket and the wire tie also just pop them off and move them out of the way. Remove the bracket completely. You will not use this with the new IM.
Unbolt the cable bracket on the right side of the IM let it hang
Unplug both of the vaccume hoses on the back of the IM
Unbolt the TB and move it upside down to the right, out of the way.
Ok now go underneath the car remove both of the IM support brackets. They are the black metal brackets on either side of the oil filter.
Unplug the breather hose coming off of the block.
Unscrew and remove the bolt on the drivers side and the 3 nuts going towards the passenger side. Leave the far pass side bolt for when you go up top again. Don’t Lose the hardware.
Once back on top get that last bolt on the Pass side. Use your wrench and access it going in from the side.
Take off the 2 easy access elongated bolts.
Now the trick. That top center bolt is a tight squeeze so get your ¼ drive, short, 12mm socket, and slip it on the bolt head. Then get your ¼ socket wrench and slip into the socket and unscrew. They do not fit in there together. Take them out one at a time.
That’s it! Pull the IM off of the studs and remove it With Out the injectors.
Assembly:
Get the Loctite and use it on the brass hose fittings for the back of the new IM. Little one on top and the big one on the bottom.
Get the bolts that came off the hose/wire bracket from the left of the TB loctite those and put them in the holes on the left of the TB. The bracket wont fit so you need to plug those holes.
Take off the MAP sensor from the old one and install on the new one Use Loctite on the screw.
Take off the 4 old blue gaskets from the runners on the old manifold, clean them and install them onto the new one. If you bought new ones than install those.
Back to the car.
If you bought a new manifold gasket (metal one) than do the following. Pull the injector manifold off and flip it up out of the way. Get a clean rag and wipe the surface of the head til its clean. Same with both sides of the injector manifold. Slip on the new gasket and the injector manifold.
If you are reusing the gasket (not recommended ) than do not remove the injector manifold. Just clean the side that the IM attaches to.
OK install the new IM. Make sure that all of the injector plugs are out of the way then bolt it back up the same way you took the other off.. EXCEPT! now use the 8x45mm bolt and wave washer for the far drivers side. Tighten all the rest of the bolts first. Then go ahead and tighten the new one last.
While you are under the car go ahead and install the breather filter on the block with a new hose clamp.
Now use the new hose clamps for the vaccume hoses in the back of the IM. Nice and tight no leaks.
Now get the hondabond and put a nice bead of it in the groove that goes around the TB hole on the IM.
Get the spacer and set it in place with the groove on it facing up.
Put in the blue TB gasket in the groove on the spacer.
Push the spacer down and center it on the hole. Use your finger and wipe away excess honda bond from both holes.
Put the TB back in place and just put 2 of the new allen screws in the corners to keep the TB centered.
DO NOT TIGHTEN THEM.
Get the loctite and put it on the other 2 Allen screws install these and snug them down.
Pull out the other 2 loctite them and go ahead and tighten them all down.
Now the tricky part. See Photo for reference
link to pic
The 18 6mm flat washers are used for spacers on the cable bracket right of the TB.
Get 2 stacks of 9 flat washers and loctite or honda bond them together. It doesn’t have to seal or anything but it makes the next step easier.
Get the cables situated so they are routed correctly.
Loctite the 6x25 bolts with the wave washer already installed on it.
Put both stacks of washers over their holes.on the IM.
Line up the cable bracket carefully over the washers and screw the bolts into place and tighten them down.
Pull out the coolant plug bots and install the coolant hoses back onto the TB.
Plug in all of the plugs and take off that ugly masking tape.
Reinstall your intake put the wheel back on if you took it off.
Let the car down and tighten the lugs on the wheel.
Reset the ECU by pulling its fuse and putting it back in.
Let it set for a while to let the loctite and hondabond do their thing.
You may have to adjust the throttle cables a bit. Mine where fine
Start it up and go. If the car idle’s from 2000 to 1000 RPM after being warmed up then you have a vacume leak and need to find it and fix it.
This is to be used as a guide. I am showing you what worked for me. Actual installation should be done by a professional.
I am not responsible for anything resulting from following this DIY.
Peace
Ok here is the list of stuff you’ll need on hand before you start the install.
Jack and 2 jack stands
2 6x25mm bolts 1.25 thread pitch
2 6mm wave or lock washers
18 6mm flat washers.
2 8mm or half inch bolts to use as plugs 2or3 inches long
1 8x45mm bolt with a 1.25 thread pitch and a wave washer for the same.
1 tube of loctite thread locker med. Strength
1 tube of hondabond
3 small hose clamps
allen socket to fit the new Throttle body bolts
12mm wrench
13mm wrench
10mm socket
12mm short socket ¼ drive
and of course the ¼ drive socket wrench
pliers
and tools to take off your intake.
Jack up the front of the car and support with jack stands (taking off the left wheel helps but is not nec.)
Take off the air intake of your choice, and throw it in the trunk.
Unplug all the wire plugs and label the with masking tape so you don’t forget where they go..injector plugs also.
Label the top coolant hose going to the pass side of the TB (Throttle Body) Unplug both of them and replug them with the 2 bolts.
Unbolt the bracket on the pass side of the IM (Intake Manifold) remove the plactic clip holding the 2 big hoses from the bracket and the wire tie also just pop them off and move them out of the way. Remove the bracket completely. You will not use this with the new IM.
Unbolt the cable bracket on the right side of the IM let it hang
Unplug both of the vaccume hoses on the back of the IM
Unbolt the TB and move it upside down to the right, out of the way.
Ok now go underneath the car remove both of the IM support brackets. They are the black metal brackets on either side of the oil filter.
Unplug the breather hose coming off of the block.
Unscrew and remove the bolt on the drivers side and the 3 nuts going towards the passenger side. Leave the far pass side bolt for when you go up top again. Don’t Lose the hardware.
Once back on top get that last bolt on the Pass side. Use your wrench and access it going in from the side.
Take off the 2 easy access elongated bolts.
Now the trick. That top center bolt is a tight squeeze so get your ¼ drive, short, 12mm socket, and slip it on the bolt head. Then get your ¼ socket wrench and slip into the socket and unscrew. They do not fit in there together. Take them out one at a time.
That’s it! Pull the IM off of the studs and remove it With Out the injectors.
Assembly:
Get the Loctite and use it on the brass hose fittings for the back of the new IM. Little one on top and the big one on the bottom.
Get the bolts that came off the hose/wire bracket from the left of the TB loctite those and put them in the holes on the left of the TB. The bracket wont fit so you need to plug those holes.
Take off the MAP sensor from the old one and install on the new one Use Loctite on the screw.
Take off the 4 old blue gaskets from the runners on the old manifold, clean them and install them onto the new one. If you bought new ones than install those.
Back to the car.
If you bought a new manifold gasket (metal one) than do the following. Pull the injector manifold off and flip it up out of the way. Get a clean rag and wipe the surface of the head til its clean. Same with both sides of the injector manifold. Slip on the new gasket and the injector manifold.
If you are reusing the gasket (not recommended ) than do not remove the injector manifold. Just clean the side that the IM attaches to.
OK install the new IM. Make sure that all of the injector plugs are out of the way then bolt it back up the same way you took the other off.. EXCEPT! now use the 8x45mm bolt and wave washer for the far drivers side. Tighten all the rest of the bolts first. Then go ahead and tighten the new one last.
While you are under the car go ahead and install the breather filter on the block with a new hose clamp.
Now use the new hose clamps for the vaccume hoses in the back of the IM. Nice and tight no leaks.
Now get the hondabond and put a nice bead of it in the groove that goes around the TB hole on the IM.
Get the spacer and set it in place with the groove on it facing up.
Put in the blue TB gasket in the groove on the spacer.
Push the spacer down and center it on the hole. Use your finger and wipe away excess honda bond from both holes.
Put the TB back in place and just put 2 of the new allen screws in the corners to keep the TB centered.
DO NOT TIGHTEN THEM.
Get the loctite and put it on the other 2 Allen screws install these and snug them down.
Pull out the other 2 loctite them and go ahead and tighten them all down.
Now the tricky part. See Photo for reference
link to pic
The 18 6mm flat washers are used for spacers on the cable bracket right of the TB.
Get 2 stacks of 9 flat washers and loctite or honda bond them together. It doesn’t have to seal or anything but it makes the next step easier.
Get the cables situated so they are routed correctly.
Loctite the 6x25 bolts with the wave washer already installed on it.
Put both stacks of washers over their holes.on the IM.
Line up the cable bracket carefully over the washers and screw the bolts into place and tighten them down.
Pull out the coolant plug bots and install the coolant hoses back onto the TB.
Plug in all of the plugs and take off that ugly masking tape.
Reinstall your intake put the wheel back on if you took it off.
Let the car down and tighten the lugs on the wheel.
Reset the ECU by pulling its fuse and putting it back in.
Let it set for a while to let the loctite and hondabond do their thing.
You may have to adjust the throttle cables a bit. Mine where fine
Start it up and go. If the car idle’s from 2000 to 1000 RPM after being warmed up then you have a vacume leak and need to find it and fix it.
This is to be used as a guide. I am showing you what worked for me. Actual installation should be done by a professional.
I am not responsible for anything resulting from following this DIY.
Peace
Registered!!
Joined: Jun 2003
Posts: 115
Likes: 0
From: Ft. Lauderdale
Rep Power: 0 i know i read about this kms thing somewhere else on the forums, but now i can't find it. djmota, how do you like it so far? is it performing as well as you'd like? again, sorry i don't know where else this is...i searched, but couldn't find it.
Thread Starter
Joined: Jun 2002
Posts: 3,242
Likes: 0
From: so cal djmota=oscar
Rep Power: 323 Yes I'm feeling the same as you and everyone else. Check the KMS#2 thread in the other forum theres a reply from John at KMS. And a whole lot of other opinions.
Thread Starter
Joined: Jun 2002
Posts: 3,242
Likes: 0
From: so cal djmota=oscar
Rep Power: 323 AzNmiKex215 Nope all you get is the manifold the rest you've got to figure out for yourself. In this case I figured it out for ya. A trip to the hardware store and your set.
Skunk2ner Nope to that also not smog legal. Doubt most cops or smog techs would know the difference between stock and not.
Skunk2ner Nope to that also not smog legal. Doubt most cops or smog techs would know the difference between stock and not.
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