I finally did the deed today and removed my AIV system from my zed. Coming from someone who has never done anything mechanical i think i did a pretty good job on the removal and i thought id write up a tech guide while i was at it so everyone could see what i did and or use this for hgelp doing their own removal someday.

 

Time Taken:

3 hours Approximately

 

Tools Needed:

-Phillips head Screwdriver

-10mm Socket and Ratchet

-Pilers

 

Related Links:

 

US Spec AIV Removal (Twin Turbo) - http://s95014253.onlinehome.us/63104/137858.html

 

US Spec AIV Removal (Non-Turbo) - http://www.300zxclub.com/showthread.php?t=107054

 

Step 1: Jacking the Car

 

- First thing you need to do is jack the front of the car. For Safety i used jack stands to hold the car up. You dont need to jack both sides up but it does make the removal go quicker and allows for more room to work in under the car.

 

http://i90.photobucket.com/albums/k276/DJ_Party_Favor/JackTheCarOfftheGround.jpg

 

Step 2 : Passnage Side Fender Lining Removal

 

- I decided to take the passenger side AIV off first as this side is the easiest to remove duie to not as many obstructions in the way of the AIV airbox. Here you can see the Fender lining which covers 3/4s of the fender well for the wheel. Dotted in red are the plastic fasteners and screws which need to be removed inorder to get the lining off the car. The are 5 plastic fasters and 9 Phillips head screws in total. If you have stock mud flaps these need to be removed as well. When the lining is removed you can see the AIVs bolted to the chassis.

 

http://i90.photobucket.com/albums/k276/DJ_Party_Favor/RHWheelOffREDDots.jpg

 

NOTES: To removed the plastic Fasteners push the middle part of the fastener inwards.

 

Step 3: Removing Passnage Side AIV Unit and Airbox

 

- There are only 4 10mm bots that secure the AIV unit to the car they are located in red in the photo. Next remove the upper rubber tubing that connects to the AIV Airbox by losening the Clamps and pulling the hoses off the Airbox. Then remove the lower rubber tubing that connectors to the exhaust metal pipes.

 

http://i90.photobucket.com/albums/k276/DJ_Party_Favor/RHAIVUnitREDDOTS.jpg

 

- The Airbox is held to the chassis by a black bracket with another bracket on top of it for the indicator connector. the brackets are screwed down by 2 10 mm screws.Once you have removed the screws and brackets from the chassis u have to fiddle with the box to get it out but if u loosen the zipties it would be much easier to remove the box. Once the box is out screw the Indicator connector bracket back in.

 

http://i90.photobucket.com/albums/k276/DJ_Party_Favor/RHAIVAirboxREDDOTS.jpg

 

- Once the AIV has been removed its a good idea to clean any dirt build up in that area. I used a brush and vacumm cleaner to get as much as dirt out as i could. The this is what everything will look like from now on.

 

http://i90.photobucket.com/albums/k276/DJ_Party_Favor/DirtSpotOnFender.jpg

 

http://i90.photobucket.com/albums/k276/DJ_Party_Favor/RHSideChassisWithoutAIV.jpg

 

http://i90.photobucket.com/albums/k276/DJ_Party_Favor/RHSideFenderWithoutAirbox.jpg

 

Step 4: Drivers Side Fender Lining Removal

 

- Same as the Passnage Side, for me i had mostly bots instead of Fasteners. All the red dots are screws which need to be removed.

 

http://i90.photobucket.com/albums/k276/DJ_Party_Favor/LHWheelOffREDDOTS.jpg

 

Step 5: Removing Drivers Side AIV and Airbox

 

- As with the Passnage side there are 4 10mm bolts that hold the unit onto the chassis,

 

http://i90.photobucket.com/albums/k276/DJ_Party_Favor/LHAIVunitREDDOTS.jpg

 

- The Drivers Side Airbox bracket has the starter relay bracket connected to it like the indicator connector bracket was. Once the 2 10mm bolts are removed replace the starter relay bracket back in its original spot. Again removing the airbox is difficult with alot more wirting looms to worry about this time, but take your time and you should be able to wiggle the box out eventually. Then remove the lower rubber tubing that connectors to the exhaust metal pipes.

 

- Again clean the fender with a brush and the units are now gone from the car.

 

http://i90.photobucket.com/albums/k276/DJ_Party_Favor/LHSideChassisWithoutAIV.jpg

 

http://i90.photobucket.com/albums/k276/DJ_Party_Favor/LHSideFenderWithoutAirbox.jpg

 

Step 6: Removing AIV Solenoid

 

- The AIV solenoid is located on the Drivers side of the car inside the engine bay. There is a black bracket that holds the solenoid to the car, remove the 2 10mm bolts from the bracket and then u must remove another 10mm bolt at the back of the solenoid to remove it from the bracket. Once the solenoid is removed place bracket back in its original spot.

 

 

 

Step 7: What To Do with the rubber Hoses

 

-The Hoses for the AIVs are connected to a T pipe, so can be removed from either the AIVs(which i did) or the AIV Solenoid and then pulled out through the wiring looms connectors its connected to along the firewall. The top hose on the solenoid connects to the Balance tube and the bottom hose to the ERG Solenoid. For me im going to cut the original hosing and then ziptie the hose back on its self to create a seal over the metal connections for the balance tube and ERG pipe.

 

As for the connector on the front of the Solenoid, u need to push the metal U wire out to disconnect the connector. As this wire connects to the wiring loom which is covered by plastic tubing and tape i left it in the engine bay but moved it to this position using one of the extra clips from the AIV system.

 

 

Step 8: Exhaust Piping

 

- For now im leaving the Metal pipes that connect directly to the exhaust front pipes and get them blocked by an exhaust shop later, unfortunately leaving the car like is make an exhaust sound at the front of the car.

 

 

Step 9: Putting Everything Back Together

 

- To finish off the removal you have to put everything back together again. Pretty straight forward just a reservse of what u just did. and this is what u are left with afterwards

 

 

 

 

 

GOOD REDDENS!!!

Excellent write up buddy, keep em coming :D

can we sticky this

To block the balance tube and EGR, i was told to use a vaccum cap which i found at a local hardware store. They fitted the connectors perfectly

 

 

 

 

And here is the new look for engine bay in the area where the solenoid was. So much more room now