VACUUM PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

id0411008036s8

1.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

3.  Pinch open the clamp using pliers and disconnect the vacuum hose from the vacuum pump. (See VACUUM HOSE REMOVAL/INSTALLATION.)

4.  Remove the following parts:

(1)  Air cleaner cover (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
(2)  Air cleaner element (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
(3)  Flesh-air duct (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
(4)  Air cleaner case (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
(5)  Air hose (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
(6)  Air inlet pipe (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

5.  Remove the turbocharger air outlet hose along with the air intake pipe. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

6.  Disconnect the CMP sensor connector. (See CAMSHAFT POSITION (CMP) SENSOR INSPECTION [SKYACTIV-D 2.2].)

7.  Remove the CMP sensor wiring harness from the lower case.

8.  Perform the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 2.2].)

9.  Remove the water pipe assembly installation bolts, then set the water pipe assembly out of the way. (See SUPPLY PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

10.  Remove the fuel return pipe (fuel injector side). (See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

11.  Remove the fuel feed pipe installation bolt from the lower case. (See SUPPLY PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

12.  Disconnect the fuel return hose No.3 from the lower case. (See LOWER CASE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

13.  Remove the lower case installation bolts. (See LOWER CASE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

14.  Remove in the order shown in the table.

15.  Install in the reverse order of removal.

16.  Perform the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-D 2.2].)

am6zzw00008770

1
Vacuum tube
2
Bolt
3
Vacuum pump
(See Vacuum Pump Removal Note.)
(See Vacuum Pump and O-ring Installation Note.)
4
O-ring
(See Vacuum Pump and O-ring Installation Note.)


Vacuum Pump Removal Note

1.  When removing the vacuum pump, place a rag under the installation surface of the vacuum pump so that engine oil does not get on other parts.

2.  Remove the vacuum pump.


Vacuum Pump and O-ring Installation Note

1.  Rotate the vacuum pump by hand to drain the remainder of the engine oil in the vacuum pump.

2.  Degrease the O-ring installation groove and installation surface.

3.  Install the new O-ring to the vacuum pump.

Caution
•  When cleaning away the remaining silicone sealant on the cylinder head, insert a cloth into the oil passage and be careful not to allow silicone sealant to penetrate the oil passage. Otherwise, silicone sealant may penetrate the oil passage.
•  Use a cloth when blocking the oil passage. If a shop paper towel is used, pieces of the oil soaked towel may break off and enter the oil passage.

4.  Insert a cloth into the oil passage shown in the figure.

am3zzw00017994

5.  Scrape the cylinder head from the inside to the outside using a scraper and clean away the remaining silicone sealant on the cylinder head so that it does not get in the cylinder head.

am3zzw00017995

•  If silicone sealant gets in the cylinder head, blow it out using compressed air.

6.  Clean the cylinder head.

Caution
•  Be careful not to apply a large quantity of silicone sealant. Otherwise, the silicone sealant may overlap the O-ring of the vacuum pump and block the oil passage of the cylinder head.
•  Install the vacuum pump before silicone sealant dries.

7.  Apply silicone sealant (TB1217D) to the positions shown in the figure.

am6zzw00008493

8.  Install the vacuum pump.