Variable Induction System: Service and Repair

1. REMOVE DATA LINK CONNECTOR 1 (DLC1) BRACKET
- Disconnect the DLC1 from the bracket.
- Disconnect the VSV connector.
- 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





- Remove the bolt, DLC1 bracket and VSV assembly.
2. REMOVE EGR PIPE

(See step 3 in injectors removal)





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

INSTALLATION HINT: Apply soapy water on the O-ring.

- Remove the O-ring from the dipstick guide.

INSTALLATION HINT: Use a new O-ring.






4. DISCONNECT VACUUM HOSES
- Disconnect these vacuum hoses:
(1) Vacuum hose (from actuator) from No.1 vacuum pipe
(2) Vacuum hose from air intake chamber
(3) Vacuum hose from hose clamp
(4) Brake booster vacuum hose from union





5. DISCONNECT NO.2 VACUUM PIPE AND VSV ASSEMBLY
- Disconnect the 2 vacuum hoses from the vacuum control valve set.
- Remove the 2 nuts, and disconnect the No.2 vacuum pipe from the air intake chamber and intake manifold.

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





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

INSTALLATION HINT: Use 2 new gaskets.

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

- 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.lb.)

- 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.lb.)

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

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





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

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

INSTALLATION HINT: Place the gasket so the protrusion faces the intake chamber.





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.lb.)





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