Honda-Tech - Honda Forum Discussion - how to install Skunk2 intake manifold on an ls...

To OP this is based off of a blox but should help out alot.

<U>BLOX Intake Manifold Install for a 1995 Acura Integra GSR</U>

I am making this write-up because there is a real lack of quality information on the install of the BLOX Intake Manifold on H-T. Additionally, the BLOX IM does not come with any type of instructions at all. A lot of the ÂofficialÂ IM posts do not have all the information needed and I found in my installation there is some misinformation out there too. This install is for a BLOX IM but it should also work for the Skunk2 IM from what I have seen, as they are relatively the same. Below are the parts needed for this install. All these parts are recommended for a COMPLETE install, not a half-assed job.

Parts needed:
-BLOX Intake Manifold
-New intake manifold gasket (Honda #17105-P72-004 or Hondata gasket)
-New throttle body gasket Â (Honda #16176-P30-004)
-(3) M6x1.00x22mm bolts (for fuel rail)
-(2) M6x1.00x2 inch bolts (for fuel filter relocation)
-(6) M8x1.25x50mm studs (for intake manifold)
-Air intake from Integra Type R (OEM or aftermarket)
-3/8Â x 3Â of coolant line
-5/16Â x 3Â of vacuum hose
-1/4Â I.D. Vacuum line for charcoal canister
-Chipped P28 ECU
-(Optional) Piece of angle iron to mount EVAP purge solenoid
I recommend buying and installing the below throttle cable parts so that your throttle cable is not sticking up with the stock one.
-(Optional) Integra Type R throttle cable (Honda #17910-ST7-R01)
-(Optional) Integra Type R throttle wire stay (Honda #16411-P73-000)
-(Optional) Non-GSR B or D-series throttle body pulley and spring

1. First uninstall and remove the stock intake manifold/gasket. I did this with the engine out of the car. I canÂt imagine how difficult this is to do with it in the car, but people do it all the time so good luck to you. The IM gasket can be difficult to get off. I used some heat from a propane torch and it worked great or there are liquid gasket removers that you can get at car repair stores also. I found it easier to remove the gasket with the IM studs removed. To do this put 2 bolt on the stud, tighten them together, and then loosen the stud by using the inner nut.
http://www.sjusko.com/BLOX/helm_IM.jpg

2. I started by installing the new, longer studs to replace the top 6 stock studs. I used a Hondata IM gasket and with this gasket those studs were too short. I only got maybe 2 turns on each nut. The lower 4 studs are long enough for the whole nut to thread on.
http://www.sjusko.com/BLOX/IM_studs.jpg

3. You want to extend the Idle Air Control Valve (IACV) wires about 3-4 inches before you install the IM. These are the only wires that need to be extended or messed with.
http://www.sjusko.com/BLOX/wires.jpg

4. Run a new vacuum line from the PCV valve upwards. Leave it long so that you can cut it to length later.
http://www.sjusko.com/BLOX/pvc1.jpg
http://www.sjusko.com/BLOX/pvc2.jpg

5. (Optional) If you are using the ITR throttle cable, you should install the non-GSR throttle plate and spring onto your stock TB now. It is straightforward but can be difficult because of the spring so it is best to do it while out of the car.

If you use a throttle plate from a B18A (and possibly more engines) it has an ear-shaped throttle plate. When using this plate on the GSR TB, the adjusting screw needs to be adjusted out because it will be holding the TB open a tiny bit. When I got my car running I could not get my idle to go down. I had no vacuum leaks or anything. It turns out that this set screw was holding the TB open a bit. You may have to further adjust this screw when the car is running to get it just right.
http://www.sjusko.com/BLOX/ear.jpg

Adjust the non-adjustable screw <IMG NAME="icon" SRC="https://honda-tech.com/forums/images/smilies/emsmilep.gif" BORDER="0"> . Loosen the 7mm nut and then adjust the screw with a small allen key (I forget the exact size)
http://www.sjusko.com/BLOX/helm_tbscrew.jpg

6. Remove the throttle body from the stock IM and install it using a new gasket to the BLOX IM (14 ft. lbs.)

7. Remove the Idle Air Control Valve (IACV) from the stock IM. Next, it is a good idea to clean the IACV because if dirty it can negatively effect your idle or even trigger a check engine light and ECU code. Clean the IACV with some carb cleaner by spraying it inside the 2 air holes. Spray for a good 30 seconds and then spray out with an air compressor for about 2 minutes to make sure no moisture resides in it. Then install it on the BLOX IM insuring the O-ring is used (16 ft. lbs.)

10. Remove the fuel rail and injectors from the stock IM. Install the injectors into the BLOX IM by first setting the gaskets into the manifold and then pushing the injectors into the IM. Then install the fuel rail onto the injectors using the (3) M6x1.00x22mm bolts (8 ft. lbs.). DO NOT use the stock brown spacers between the fuel rail and IM. Also, the stock 3 studs on your GSR IM will not work. They are not threads down long enough.
http://www.sjusko.com/BLOX/fuel.jpg
http://www.sjusko.com/BLOX/helm_fuel.jpg

11. (Optional) Remove the stock throttle cable and install the ITR throttle cable.

12. Bolt the BLOX intake manifold to the head using the IM gasket (17 ft. lbs.)

13. Run new coolant lines from the head to the Fast Idle Thermo Valve (FITV), FITV to IACV, and IACV to the head. Also connect the line coming from the PVC to the top vacuum outlet.
http://www.sjusko.com/BLOX/water1.jpg
http://www.sjusko.com/BLOX/water4.jpg
http://www.sjusko.com/BLOX/water2.jpg

14. The EVAP purge solenoid does not have a place to bolt to the new manifold. Because of this it can be mounted to the firewall, which would involve extending the wires to it, or mounting it close to the stock location. I chose the later using a piece of angle iron and I did not have to extend the wires. Also, bolt the Intake Air Temp (IAT) sensor to the new manifold.
http://www.sjusko.com/BLOX/evap.jpg

15. Run new vacuum lines from the IM to the fuel pressure regulator. Also, reconnect the fuel return line. Then run a vacuum hose from the IM to the bottom nipple on the EVAP purge solenoid. Then run one from the top nipple on the EVAP purge solenoid to the charcoal canister. You will also need to replace the stock vacuum line coming from the charcoal canister to the throttle body. It is a tight fit, so use a longer one.
http://www.sjusko.com/BLOX/vacuum.jpg
http://www.sjusko.com/BLOX/helm_vacuum.jpg

16. Connect the 4 electrical plugs to the 4 sensors on the IM (EVAP purge solenoid, IACV, IAT, TPS).
http://www.sjusko.com/BLOX/elec.jpg

17. Connect the throttle cable to the throttle cable bracket using the throttle cable holder. Adjust cable accordingly.
http://www.sjusko.com/BLOX/helm_cable1.jpg
http://www.sjusko.com/BLOX/helm_cable2.jpg

18. The stock fuel line feed line is too short stock. If you try connecting it to the IM it will be overstretched and will be touching the intake arm. I have searched on Honda-Tech for a solution and some people have suggested using a 1999-2000 Civic SI fuel feed line. THIS DOES NOT WORK! I bought it from the dealer and it is the same exact length and the GSR one. So, until I find a longer fuel line I have pushed the fuel filter away from the firewall. This gives the fuel line more slack so that it does not touch the intake arm. I used longer bolts to hold the filter on and used some nuts as spacers. Although this looks ghetto it is much safer than having your fuel line spring a leak from rubbing against the intake and being overstretched.
http://www.sjusko.com/BLOX/fuelfeed.jpg

19. Install the Type R intake. A LS intake will also fit but after buying one I have learned that a LS intake is about Â¼Â smaller in diameter than the GSR TB. Therefore a Type R intake should be used. The stock GSR intake arm will not fit because it is meant to be bent downward to connect to the lower GSR IM. I also used a zip-tie temporarily to give the fuel feed line additional room.
http://www.sjusko.com/BLOX/intake.jpg

20. Install P28 chipped ECU. This seems like an often missed part of this modification. This new manifold does not have butterflies in it as well as the IAB sensor on it. The stock ECU will give a code because this sensor is not connected. Also, I have heard of dips in power around the time the butterflies would open because the ECU still thinks they are there. Make the most out of this IM mod and get a chipped P28 ECU to use with it.
http://www.sjusko.com/BLOX/ecu.jpg

DONE!
http://www.sjusko.com/BLOX/done.jpg

Feel free to let me know if any corrections need to be made. I am in no way perfect <IMG NAME="icon" SRC="https://honda-tech.com/forums/images/smilies/emsmilep.gif" BORDER="0"> . I hope this is helpful for you all.

[i]Modified by Honda Hick at 10:52 PM