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Old 09-28-2011, 10:29 AM   #64
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Location: Denver, NC
What I Drive: 2004 White ZX3

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First off, blueoval23, hope you don't mind me adding all of these photos to your thread. Just working through my learning curve for the first time doing this job.

Installed the Gates 18423 hose (see previous hose photos) after a few attempts this morning. Had a problem getting the lubricated hose to stay on the intake manifold nipple while getting the hose clamp in position to tighten. Needed to write this down while it's fresh in my mind.

This is probably common knowledge for many experienced FF, but hope this information will be helpful for some.

Here is the final installation sequence that worked for me:

The cooling fan assembly needs to be removed, if it has not already been done.

Used K & N air filter seal grease on both PCV hose IDs & nipple ODs to help
the undersized hose to slip on easily.

Tighten screwdriver/socket type hose clamp on the PCV hose connection.

The photo shows how the clamps should be oriented.

Install the intake manifold & EGR tube without manifold bolts.

From the front right side of the intake manifold, slip the PCV hose
on the intake manifold nipple.

Hold the manifold as close as possible to the engine to prevent
hose from slipping off while one intake manifold bolt is installed
to hold intake manifold & PCV hose in place.

Be sure the hose did not slide off the nipple and tighten hose
clamp with a ratchet.

Hose clamps used:

Reach in under intake to install/tighten hose to intake manifold:

Installed hose clamp in bottom RH portion of photo looking from intake/air filter side:

Will put everything back together & test the ZX3 this afternoon!
2004 ZX3 2.3L 5 speed-Sold
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