VACUUM PUMP(for 2GR-FKS) INSTALLATION

PROCEDURE


  1. INSTALL VACUUM PUMP ASSEMBLY


    1. When using a new vacuum pump assembly:


      1. B005PNSC01
        *1 No. 2 O-ring
        *2 No. 3 O-ring
        B005NIZ Engine oil

        Apply engine oil to the No. 2 O-ring and No. 3 O-ring which are installed to a new vacuum pump assembly.

    2. When reusing the vacuum pump assembly:


      1. B005PNSC01
        *1 No. 2 O-ring
        *2 No. 3 O-ring
        B005NIZ Engine oil

        Apply engine oil to a new No. 2 O-ring and No. 3 O-ring and install them to the vacuum pump assembly.

    3. Apply engine oil to the inner surface of the installation hole.

    4. B005Q86C01
      *a Coupling Teeth
      *b Groove

      Install the vacuum pump assembly so that the oil pipe engages with the hole of the camshaft and the coupling teeth with the grooves on the camshaft tip.

      Note


      • Ensure that the vacuum pump assembly is installed securely.

      • Be careful not to pinch the O-ring.

    5. B005P48

      Install the vacuum pump assembly with the 3 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Note

      After installation, check that there are no gaps between the matching surfaces and that the vacuum pump assembly is not installed at an angle.

  2. INSTALL ENGINE WIRE


    1. B005NWLC01
      B005NIZ Bolt
      B005LWS Nut

      Install the engine wire with the bolt and nut.

      Torque:
      8.35 N*m  { 85 kgf*cm, 74 in.*lbf }
    2. B005NNCC01
      B005NIZ Connector
      B005LWS Bolt
      B005N37 Nut

      Install the 3 bolts and nut.

      Torque:
      Bolt
      19.1 N*m  { 195 kgf*cm, 14 ft.*lbf }
      Nut
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    3. Connect the 3 connectors.

    4. B005N7A

      Install the 2 nuts.

      Torque:
      8.35 N*m  { 85 kgf*cm, 74 in.*lbf }

    5. Engage the 2 clamps.

    6. B005L4LC01
      B005NIZ Connector
      B005LWS Bolt

      Install the bolt.

      Torque:
      8.35 N*m  { 85 kgf*cm, 74 in.*lbf }

    7. Connect the 5 connectors.

    8. B005M1HC01
      B005NIZ Connector
      B005LWS Bolt

      Install the 2 bolts.

      Torque:
      8.35 N*m  { 85 kgf*cm, 74 in.*lbf }

    9. Engage the 2 clamps and claw.

    10. Connect the 8 connectors.

    11. B005LVVC01
      B005NIZ Connector
      B005LWS Bolt

      Install the bolt.

      Torque:
      8.35 N*m  { 85 kgf*cm, 74 in.*lbf }

    12. Engage the clamp.

    13. Connect the 2 connectors.

  3. INSTALL NO. 2 ENGINE UNDER COVER

    Click here

  4. CONNECT VACUUM HOSE SUB-ASSEMBLY


    1. B005LBD

      Connect the vacuum hose sub-assembly.

  5. CONNECT HEATER WATER HOSE


    1. B005P7OC01
      *1 Inlet Heater Water Hose
      *2 Outlet Heater Water Hose

      Connect the inlet heater water hose and outlet heater water hose, and slide the 2 clips to secure them.

    2. Engage the clamp.

  6. CONNECT VENTILATION HOSE


    1. B005N6M

      Connect the ventilation hose, and slide the clip to secure it.

  7. CONNECT AIR TUBE


    1. B005QF5

      Connect the air tube to the vacuum pump assembly, and slide the clip to secure it.

  8. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY


    1. Install a new clip to the No. 1 transmission control cable bracket.

    2. B005ODOC10
      *1 Transmission Control Cable Assembly
      *2 No. 1 Transmission Control Cable Bracket
      *a Claw (A)
      *b Claw (B)

      Connect the transmission control cable assembly to the No. 1 transmission control cable bracket.

      Note


      • Make sure that the claws (A) of the clip are securely fit into the bracket holes.

      • Make sure that the transmission control cable assembly is securely installed inside of the claws (B) of the clip.

    3. Connect the transmission control cable assembly to the transmission control shaft lever with the nut.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  9. INSTALL AIR CLEANER BRACKET

    Click here

  10. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  11. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  12. INSTALL INLET AIR CLEANER ASSEMBLY

    Click here

  13. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here

  14. INSTALL COOL AIR INTAKE DUCT SEAL

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  15. INSTALL FRONT WHEEL LH

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  16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here

  17. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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  18. INSPECT VACUUM PUMP OPERATION

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