VACUUM PUMP(for 1KD-FTV, 2KD-FTV) INSTALLATION

PROCEDURE


  1. INSTALL VACUUM PUMP BEARING


    1. B0024SO

      Using a press, press in a new vacuum pump bearing to the vacuum pump shaft.

  2. INSTALL VACUUM PUMP SHAFT


    1. B0024P3N05

      Using SST and a press, press in the vacuum pump shaft to the vacuum pump housing.

      SST
      09608-04031

    2. Using snap ring pliers, install a new snap ring.

      Note

      Make sure that the snap ring is firmly installed to the groove.

  3. INSTALL VACUUM PUMP GEAR


    1. Temporarily install the woodruff key and vacuum pump gear to the vacuum pump assembly with the gear lock nut.

    2. Mount the vacuum pump gear in a vise.

      Note

      Place aluminum plates on the vise to prevent damage to the vacuum pump gear.

    3. Tighten the gear lock nut.

      Torque:
      110.3 N*m  { 1125 kgf*cm, 81 ft.*lbf }

  4. INSTALL VACUUM PUMP BLADE


    1. B0024F4C04
      *a Round End

      Apply engine oil to the vacuum pump rotor, and install the vacuum pump rotor to the vacuum pump housing.

    2. Install 5 new vacuum pump blades with the round ends facing outward.

      Tech Tips


      • Apply engine oil to the blades.

      • Make sure that the blades are flush with the vacuum pump rotor surface.

  5. INSTALL VACUUM PUMP END COVER


    1. Mount the vacuum pump assembly in a vise.

      Note

      Place aluminum plates on the vise to prevent damage to the vacuum pump assembly.

    2. Apply engine oil to 2 new O-rings.

    3. Install the 2 O-rings.

    4. Install the vacuum pump end cover and temporarily install the 3 bolts.

    5. Using a 5 mm pin punch and hammer, tap in the 2 straight pins.

    6. Tighten the 3 bolts.

      Torque:
      7.9 N*m  { 80 kgf*cm, 69 in.*lbf }

  6. INSTALL CHECK VALVE SUB-ASSEMBLY


    1. Install a new gasket and the check valve sub-assembly.

      Torque:
      73.5 N*m  { 749 kgf*cm, 54 ft.*lbf }

    2. Install 2 new gaskets and the union with the union bolt.

      Torque:
      13.7 N*m  { 140 kgf*cm, 10 ft.*lbf }

      Tech Tips

      Insert the union pin into the hole of the casing.

  7. INSTALL VACUUM PUMP ASSEMBLY


    1. Install 2 new O-rings.

    2. Install the vacuum pump assembly to the engine with the 2 nuts.

      Torque:
      20.6 N*m  { 210 kgf*cm, 15 ft.*lbf }

    3. Connect the 2 hoses to the vacuum pump assembly with the clip.

  8. INSTALL NO. 1 TIMING BELT COVER (for 1KD-FTV)

    Click here

  9. INSTALL NO. 1 TIMING BELT COVER (for 2KD-FTV)

    Click here

  10. INSTALL RADIATOR ASSEMBLY


    1. for 1KD-FTV:

      Click here

    2. for 2KD-FTV:

      Click here

  11. CHECK VACUUM PUMP ASSEMBLY

    Click here

  12. INSTALL NO. 2 ENGINE UNDER COVER (for 4WD and Pre-Runner)

    Click here

  13. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY (for 4WD and Pre-Runner)

    Click here