VACUUM PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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Replacement part

Oil and chemical type

Warning

•  A hot engine can cause severe burns. Turn off the engine and wait until it is cool before removing the exhaust system.

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

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

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

4.  Remove the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Air hose

•  Air cleaner cover

•  Air cleaner element

•  Fresh-air duct

•  Air cleaner case

•  Air inlet pipe

5.  Disconnect the blow-by heater connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

6.  Disconnect the breather hose from the cylinder head cover. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

7.  Remove the turbocharger air inlet pipe and the breather hose as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

8.  Pinch open the clamp using pliers and disconnect the vacuum hose from the vacuum pump. (See VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

9.  Detach the clip.

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10.  Remove the nuts and set the turbocharger air outlet pipe component aside. (See Turbocharger Air Outlet Pipe Component Installation Note.)

11.  Remove the nuts and set the water pipe component aside.

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12.  Disconnect the connector and clip shown in the figure.

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

14.  Remove the following parts. (See SUPPLY PUMP DATA RESET [SKYACTIV-D 2.2].)

•  Fuel feed pipe

•  Fuel return pipe (fuel injector side)

•  Fuel return hose No.2

•  Fuel return hose No.3

15.  Remove the bolts and set the lower case aside.

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16.  Remove the insulator installation bolts. (See EGR PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

17.  Set the insulator aside so that it does not interfere with the servicing for the vacuum pump removal.

18.  Remove in the order shown in the figure.

19.  Install in the reverse order of removal.

20.  Refer to the “AFTER SERVICE PRECAUTION“ and perform the fuel hose installation procedure and fuel line air bleeding.(See BEFORE SERVICE PRECAUTION [SKYACTIV-D 2.2].)

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

Vacuum Pump Removal Note

1.  When removing the vacuum pump, set a cloth to the underside of the vacuum pump installation surface so that engine oil does not get on other parts.

2.  Remove the vacuum pump.

Vacuum Pump, O-ring Installation Note

1.  Drain the remaining engine oil in the vacuum pump by manually rotating the vacuum pump.

2.  Remove any grease or dirt from the O-ring installation groove and installation surface.

3.  Install a 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.

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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.

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•  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 or equivalent) to the positions shown in the figure.

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8.  Install the vacuum pump.

Turbocharger Air Outlet Pipe Component Installation Note

1.  Install the nuts in the order shown in the figure.

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