Variable Induction System: Service and Repair

COMPONENTS FOR REMOVAL AND INSTALLATION

INTAKE AIR CONTROL VALVE REMOVAL





1. REMOVE DATA LINK CONNECTOR 1 (DLC1) BRACKET
(a) Disconnect the DLC1 from the bracket.
(b) Disconnect the VSV connector.
(c) Disconnect these hoses:
(1) PS air hose from air intake chamber
(2) Vacuum sensing hose from air intake chamber
(3) Vacuum sensing hose from fuel pressure regulator





(d) Remove the bolt, DLC1 bracket and VSV assembly.
2. A/T:
REMOVE OIL DIPSTICK AND GUIDE FOR A/T





3. REMOVE OIL DIPSTICK AND GUIDE FOR ENGINE
(a) Disconnect the fuel return hose from the clamp of the dipstick guide.
(b) Remove the bolt.
(c) Pull out the dipstick guide together with the dipstick.
(d) Remove the O-ring from the dipstick guide.

INSTALLATION HINT: Use a new O-ring.





4. REMOVE EGR PIPE
(a) Loosen the union nut of the EGR pipe.

Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)

(b) Remove the 2 bolts, EGR pipe and gasket.

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

INSTALLATION HINT: Use a new gasket.





5. DISCONNECT EGR GAS TEMPERATURE SENSOR CONNECTOR
(a) Disconnect the connector from the No.2 vacuum pipe.
(b) Disconnect the sensor connector from the wiring connector.
6. DISCONNECT NO.2 VACUUM PIPE AND VSV ASSEMBLY
Remove the 2 nuts and disconnect the vacuum pipe from the air intake chamber and intake manifold.

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

7. REMOVE AIR INTAKE CHAMBER (WITH INTAKE AIR CONTROL VALVE)





(a) Remove the 2 nuts holding the throttle body bracket to the cylinder head.

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

(b) Remove the 4 bolts and 2 nuts holding the intake air connector to the air intake chamber.

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

(c) Remove the bolt and disconnect the engine wire protector from the air intake chamber.
(d) Disconnect these hoses:





(1) 3 vacuum hoses (from No.2 vacuum pipe) from No.1 vacuum pipe
(2) Vacuum hose (from No.2 vacuum pipe) from air intake chamber





(3) PS air hose from air intake chamber
(4) Brake booster vacuum hose from air intake chamber
Remove the union bolt and 2 gaskets and disconnect the vacuum hose.

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

INSTALLATION HINT: Use the 2 new gaskets.

(5) Vacuum hose (from actuator for ACIS) from No.1 vacuum pipe





(e) Loosen the 2 nuts holding the air intake chamber stays to the cylinder head.

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

(f) Remove the 2 bolts and disconnect the 2 air intake chamber stays from the air intake chamber.

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





(g) Remove the 5 bolts, nut, air intake chamber and 2 gaskets.

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

INSTALLATION HINT: Use 2 new gaskets.

INTAKE AIR CONTROL VALVE INSTALLATION

INSTALLATION HINT: Installation is in the reverse order of removal.