Air Injection Control Valve: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DRAIN ENGINE COOLANT
3. REMOVE V-BANK COVER SUB-ASSEMBLY
4. REMOVE AIR CLEANER HOSE ASSEMBLY
5. DISCONNECT FUEL HOSE
6. DISCONNECT NO. 2 FUEL HOSE
7. DISCONNECT CONNECTORS FROM INTAKE MANIFOLD
8. DISCONNECT HOSES FROM INTAKE MANIFOLD
9. REMOVE INTAKE MANIFOLD ASSEMBLY
10. REMOVE NO. 2 AIR TUBE
a. Remove the 4 nuts and 2 gaskets, and disconnect the No. 2 air tube.
11. REMOVE NO. 3 AIR TUBE
a. Remove the 4 nuts and 2 gaskets, and disconnect the No. 3 air tube.
12. REMOVE WATER BY-PASS JOINT RR
13. REMOVE NO. 2 AIR SWITCHING VALVE
a. Remove the 2 vacuum hoses from the No. 2 air switching valves.
b. Remove the 4 bolts, 2 gaskets and the 2 No. 2 air switching valves from the water by-pass joint rear.
14. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY
15. REMOVE AIR PUMP ASSEMBLY WITH BRACKET
16. REMOVE PRESSURE SENSOR
a. Remove the vacuum hose from the pressure sensor and air switching valve.
b. Remove the 2 bolts and pressure sensor from the air switching valve.
17. REMOVE AIR SWITCHING VALVE
a. Remove the 2 bolts and air switching valve from the air pump bracket.
b. Remove the No. 1 air hose from the air switching valve and air pump.
INSTALLATION
1. INSTALL AIR SWITCHING VALVE
a. Install the No. 1 air hose to the air switching valve and air pump.
b. Install the air switching valve with the 2 bolts to the air pump bracket.
Torque: 16 N.m (163 kgf.cm, 12 ft.lbf)
2. INSTALL PRESSURE SENSOR
a. Install the pressure sensor with the 2 bolts to the air switching valve.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
b. Install the vacuum hose to the pressure sensor and air switching valve.
3. INSTALL AIR PUMP ASSEMBLY WITH BRACKET
4. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
5. INSTALL NO. 2 AIR SWITCHING VALVE
a. Install 2 new gaskets and the 2 No. 2 air switching valves with the 4 bolts to the water by-pass joint rear.
Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
b. Connect the 2 vacuum hoses to the No. 2 air switching valves.
6. INSTALL WATER BY-PASS JOINT RR
7. INSTALL NO. 3 AIR TUBE
a. Install the 4 nuts and 2 new gaskets, and connect the No. 3 air tube.
Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
8. INSTALL NO. 2 AIR TUBE
a. Install the 4 nuts and 2 new gaskets, and connect the No. 2 air tube.
Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
9. INSTALL INTAKE MANIFOLD ASSEMBLY
10. CONNECT HOSES TO INTAKE MANIFOLD
11. CONNECT CONNECTORS TO INTAKE MANIFOLD
12. INSTALL NO. 2 FUEL HOSE
13. INSTALL FUEL HOSE
14. INSTALL AIR CLEANER HOSE ASSEMBLY
15. INSTALL V-BANK COVER SUB-ASSEMBLY
16. ADD ENGINE COOLANT
17. CHECK FOR ENGINE COOLANT LEAK
18. CHECK FOR FUEL LEAK