VACUUM PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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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 cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 2.2].)

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

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

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

5.  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].)

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

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

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

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

10.  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].)

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

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

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

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

15.  Remove in the order shown in the table.

16.  Install in the reverse order of removal.

17.  Perform the “AFTER SERVICE PRECAUTION”. (See AFTER 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 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.

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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.