KL03 IAC vacuum port adapter procedure
Burnt (Joel) and I adapted the 03 IAC to work off of the PCV vac. I bought the hoses from my local Pep Boys. You basically want to T into the PCV hose and provide vac for the IAC. The hose for the PCV is small (5/16") and the IAC vac port is huge (21/32"). You can make an adapter out of a short length of 19/32" rubber hose. It's stretchy enough to accomodate the 21/32" size of the IAC port but small enough to snug down onto the outer diameter of the 5/16" hose with the help of a hose clamp. You want to minimize the length of the 19/32" hose since it has a comparably thin wall and is prone to collapse. All you will need is ~2.5" of hose. ~1.25" to shove the small hose into and ~1.25" to slide over the IAC vac port. Permatex#2 is used to seal any potential vac leaks at the 19/32" to 5/16" snug fitting. Although I doubt that much oil will get to the IAC (the IAC mechanism probably only moves ~5cc's of air and doesn't ever flow any more air than that), you can protect the IAC with a 5/16" fitting fuel filter that is spliced inline of the PCV hose between the T and the PCV valve. Burnt and I tested out the system and it worked perfectly. No brake performance degredation, the idle bumps up when you turn on the A/C or add an electrical load.
Here is the procedure:
Tools needed:
-Flat screwdriver or 1/4" nut driver
-scissors
Parts needed:
-3.5 feet of 5/16" rubber fuel line (2 feet if you reuse your stock PCV hose)
-1 foot of 19/32" rubber hose (it's labelled as anti-smog hose)
-two 1/2" to 1-1/4" adjustable hose clamps
-one 5/16" plastic or metal vacuum "T"
-Permatex Seal-a-Gasket #2 non-hardening gasket sealer
-(optional) 7 small 1/2" hose clamps
-(optional) one fuel filter 5/16" ends
Procedure:
1) remove intake system
2) cut a 2.5" length of 19/32" rubber hose
3) Apply the Permatex #2 onto half of the inside of the 19/32" hose piece
4) Apply Permatex #2 onto the outer tip of one end of the 2 foot length of the 5/16" hose (~1" worth)
5) slide the prepped end of the 5/16" hose into the prepped end of the 19/32" hose. Use a hose clamp to tighten down the large hose until it snugs down onto the small hose.
6) install the completed large side of the hose onto the IAC vac port and clamp it down with the 2nd hose clamp
7) install the small side of the hose onto the 5/16" vacuum T
8) Install the T midway between the 2 halves of the PCV hose (stock hose cut in half or replacement 5/16" hose [2 pieces])
Recommended #1: install fuel filter inline of the PCV hose between the T and the PCV valve.
Recommended #2: for the best vacuum integrity, use hose clamps at all hose to port connections.
Optional: you can substitute the Permatex with tire repair "glue" (vulcanizing compound). Just rough up the inner surface of the large tube and the outer surface of the small tube. Apply some "glue" and clamp the 2 pieces down. This should bond the 2 pieces together permanently. Allow to dry for 1 day.
Please provide feedback to improve upon the directions if needed.
Some pics:
Adapter hose components
Adapter hose completed
Adapter hose attached to KL03 IAC
Adapter hose installed
PCV hose Tee'd with new IAC adapter hose
Pic of optional PCV fuel filter mod