Intake Air Plenum: Service and Repair

REMOVAL





1. REMOVE RH ENGINE MOUNTING STAY
2. REMOVE V-BANK COVER
Using a 5 mm hexagon wrench, remove the 2 nuts.





Disconnect the 2 clips, and remove the cover.

3. REMOVE AIR INTAKE CHAMBER ASSEMBLY
Disconnect these cables and connectors:
^ Accelerator cable
^ A/T throttle cable
^ Throttle position sensor connector
^ IAC valve connector
^ EGR gas temperature sensor connector
^ A/C idle-up valve connector
^ VSV connector for ACIS
^ VSV connector for fuel pressure control
^ California:
^ VSV connector for EVAP
^ VSV connector for EGR
^ DLC1 from bracket on intake air control valve
Remove the 2 nuts, and disconnect the PS pressure tube from the No.1 engine hanger.




Disconnect the hoses, cables, strap and clamp:
(1) Brake booster vacuum hose from intake air control valve for ACIS
(2) PCV hose from PCV valve on RH cylinder head
(3) Ground strap and cable from intake air control valve for ACIS
(4) Ground cable from air intake chamber




(5) Vacuum hose clamp from fuel pipe
(6) 2 water bypass hoses from throttle body
(7) Air assist hose from throttle body
(8) 2 PS air hoses from air intake chamber
(9) California: EVAP hose from pipe on emission control valve set
(10) 2 vacuum hoses from pipes on cylinder head rear plate
(11) Vacuum sensing hose from fuel pressure regulator
(12) Engine wire clamp from emission control valve set





(13) Except California: 2 EVAP hoses (from TVV) from pipe on throttle body
(14) Except California: EVAP hose from hose clamp
(15) Except California: EVAP hose (from charcoal canister) from pipe on throttle body





Remove the 2 bolts and No.1 engine hanger.
Remove the 2 bolts and air intake chamber stay.
Remove the 4 nuts, No.2 EGR pipe and 2 gaskets.





Disconnect the hose from the VSV for EVAP.
Using an 8 mm hexagon wrench, remove the 2 bolts, 2 nuts, the air intake chamber assembly and gasket


INSTALLATION

1. INSTALL AIR INTAKE CHAMBER ASSEMBLY




(a) Using an 8 mm hexagon wrench, install a new gasket and the air intake chamber assembly with the 2 bolts and 2 nuts.
Uniformly tighten the bolts and nuts in several passes.

Torque: 43 N.m (440 kgf.crn, 32 ft.lbf)

(b) Connect the hose to VSV for EVAP.





(c) Install 2 new gaskets and No.2 EGR pipe with the 4 nuts.

Torque: 12 N.m (120 kgf.cm, 9 ft.lbf)

(d) Install the No.1 engine hanger with the 2 bolts

Torque: 39 N.m (400 kgf.cm, 19 ft.lbf)

(e) Install the air intake chamber stay with the 2 bolts.

Torque: 19.5 N.m (200 kgf.cm, 14 ft.lbf)

(f) Connect the hoses, cables, strap and clamp:
^ Brake booster vacuum hose to intake air control valve for ACIS
^ PCV hose to PCV valve on RH cylinder head
^ Ground strap and cable to intake air control valve for ACIS

Connect the ground cable and strap with the nut.

Torque: 14.5 N.m (145 kgf.cm, 10 ft.lbf)

^ Ground cable to air intake chamber
^ Vacuum hose clamp to fuel pipe
^ 2 water bypass hoses to throttle body
^ Air assist hose to throttle body
^ 2 PS air hoses to air intake chamber
^ California: EVAP hose to pipe on emission control valve set
^ 2 vacuum hoses to pipes on cylinder head plate
^ Vacuum sensing hose to fuel pressure regulator
^ Engine wire clamp to emission control valve set
^ Except California: 2 EVAP hoses (from TVV) to pipe on throttle body
^ Except California: EVAP hose to hose clamp
^ Except California: EVAP hose (from charcoal canister) to pipe on throttle body

(g) Install the PS pressure tube with the 2 nuts.
(h) Connect these connectors and cables:
^ Throttle position sensor connector
^ IAC valve connector
^ EGR gas temperature sensor connector
^ A/C idle-up valve connector
^ VSV connector for ACIS
^ VSV connector for fuel pressure control
^ California: VSV connector for EVAP
^ VSV connector for EGR
^ DLC1 to bracket on intake air control valve
^ Accelerator cable
^ A/T throttle cable

2. INSTALL V-BANK COVER
3. INSTALL RH ENGINE MOUNTING STAY