Variable Induction System: Service and Repair

COMPONENTS FOR REMOVAL AND INSTALLATION




REMOVAL
1. REMOVE DATA LINK CONNECTOR 1 (DLC1) BRACKET.
- Disconnect the DLC1 from the bracket.
- Disconnect the Vacuum Switching Valve (VSV) connector.
- Disconnect these hoses:
- PS air hose from air intake chamber
- Vacuum sensing hose from air intake chamber
- Vacuum sensing hose from fuel pressure regulator




- Remove the bolt; DLC1 bracket and VSV assembly.

2. REMOVE EXHAUST GAS RECIRCULATION (EGR) PIPE.
- Refer to step 3 in injectors removal and step 11 in injectors installation under "Service and Repair". Fuel Injector




3. REMOVE DIPSTICK GUIDE FOR TRANSMISSION.
- Remove the mounting bolt.
- Pull out the dipstick guide together with the dipstick.

- Remove the O-ring from the dipstick guide.




4. DISCONNECT VACUUM HOSES.
- Vacuum hose (from actuator) from No. 1 vacuum pipe
- Vacuum hose from air intake chamber
- Vacuum hose from hose clamp
- Brake booster vacuum hose from union




5. DISCONNECT No. 2 VACUUM PIPE FROM AIR INTAKE CHAMBER.
- Disconnect the 2 vacuum hoses from the vacuum control valve set.
- Remove the 2 nuts and disconnect the No. 2 vacuum pipe.

Torque: 27 N.m (280 kgf.cm. 20 ft.lbf)




6. REMOVE AIR INTAKE CHAMBER.
- Disconnect the accelerator cable from the bracket.
- Remove the union bolt, brake booster union and 2 gaskets.

Torque: 29 N.m (300 kgf.cm, 22 ft.lbf)




- Remove the 2 bolts, accelerator cable bracket and hose clamp.
- Remove the 2 bolts holding the chamber stays to the air intake chamber.

Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)

- Remove the 4 bolts and 2 nuts holding the intake air connector to the air intake chamber.

Torque: 27 N.m (280 kgf.cm, 20 ft.lbf)

- Remove the 2 nuts holding the throttle body bracket to the cylinder head.

Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)

- Remove the 5 bolts, nut, air intake chamber and 2 gaskets.

Torque: 27 N.m (280 kgf.cm, 20 ft.lbf)




7. REMOVE VACUUM CONTROL VALVE SET.
- Disconnect the VSV connector.
- Remove the 2 nuts and vacuum control valve set.

Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)




8. REMOVE VACUUM TANK AND VSV.
- Remove the vacuum hose, screw and VSV from the vacuum tank.

INSTALLATION
- Installation is in the reverse order of removal.

INSTALLATION HINTS:
- Use a new O-ring.
- Apply soapy water on O-rings.
- Use new gaskets.




- Place the new gasket so the protrusion faces the intake chamber.