RM38T0EC _54 Brake _113942 BRAKE SYSTEM (OTHER) _0505309 VACUUM PUMP(for BOSCH Made) A

BRAKE SYSTEM (OTHER)  VACUUM PUMP(for BOSCH Made)  INSTALLATION  


CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)
C450863N02
6.021,1.375 6.688,1.542 0.667,0.167 5.979,1.333 6.729,1.583 0.75,0.25 5.167,1.083 5.802,0.75 5.802,0.75 5.969,0.75 false 4.729,0.854 5.313,0.521 5.313,0.521 5.479,0.521 false 5.688,1.458 6.021,1.458 false 5.583,0.417 6,0.667 0.417,0.25 10 false ● *1 5.677,1.5 6,1.75 0.323,0.25 10 false x3 6.26,0.625 6.542,0.979 0.281,0.354 18 false 1 6.094,1.375 6.813,1.552 0.719,0.177 8 false 10 (102, 7)

Procedure Part Name Code
Z101186

Z101188

Z101187

1 VACUUM PUMP ASSEMBLY 29300 (Click here) - -

*1 NO. 1 VACUUM PUMP O-RING - -
V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf) ● Non-reusable part

C450862N02
1.156,1.479 1.823,1.646 0.667,0.167 6,1 6.667,1.167 0.667,0.167 5.698,1.594 6.365,1.76 0.667,0.167 4.635,0.177 5.302,0.344 0.667,0.167 2.375,1.01 2.708,1.01 false 5.26,0.781 5.51,0.531 5.51,0.531 5.677,0.531 false 3.146,0.198 3.313,0.198 3.313,0.198 3.698,0.833 false 3.938,4.729 4.635,5.552 4.635,5.552 4.802,5.552 true 1.823,1.563 1.99,1.563 1.99,1.563 2.24,1.313 false 4.135,1.677 4.469,0.26 4.469,0.26 4.635,0.26 false 5.667,1.073 6,1.073 false 5.365,1.667 5.698,1.667 false 2.927,0.063 3.208,0.417 0.281,0.354 18 false 5 5.156,5.427 5.438,5.781 0.281,0.354 18 false 4 2.802,0.854 3.083,1.208 0.281,0.354 18 false 3 5.76,0.385 6.042,0.74 0.281,0.354 18 false 2 4.208,1.656 4.521,1.854 0.313,0.198 10 false x2 1.208,1.479 1.958,1.656 0.75,0.177 8 false 10 (102, 7) 5.74,1.583 6.49,1.76 0.75,0.177 8 false 10 (102, 7) 6.042,1 6.792,1.177 0.75,0.177 8 false 10 (102, 7) 4.688,0.177 5.438,0.354 0.75,0.177 8 false 10 (102, 7)

Procedure Part Name Code
Z101186

Z101188

Z101187

2 NO. 3 WATER HOSE CLAMP BRACKET 16575F - - -
3 VACUUM SURGE TANK 25719 - - -
4 ENGINE WIRE 82121 (Click here) - -
5 NO. 1 VACUUM HOSE CONNECTOR 44777 (Click here) - -

V100146

N*m (kgf*cm, ft.*lbf): Specified torque - -

C451172N01
5.427,1.896 6.26,2.063 0.833,0.167 5.292,0.938 5.625,0.938 false 4.156,1.771 4.49,1.771 false 5.365,2.5 5.698,2.5 false 5.094,1.979 5.427,1.979 false 6.438,0.271 6.771,0.271 false 6.24,0.115 6.521,0.469 0.281,0.354 18 false 9 5.719,0.792 6,1.146 0.281,0.354 18 false 7 4.573,1.583 4.854,1.938 0.281,0.354 18 false 8 5.781,2.333 6.063,2.688 0.281,0.354 18 false 6 5.094,2.021 5.406,2.219 0.313,0.198 10 false x3 5.479,1.896 6.396,2.052 0.917,0.156 8 false 15.4 (157, 11)

Procedure Part Name Code
Z101186

Z101188

Z101187

6 BATTERY CLAMP SUB-ASSEMBLY 74404A - - -
7 AUXILIARY BATTERY - - - -
8 ECM 89661 - - -
9 INSPECT VACUUM PUMP OPERATION - (Click here) - -

V100146

N*m (kgf*cm, ft.*lbf): Specified torque - -

CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION


HINT:

Refer to the following illustration and check which type is installed to the vehicle.

C449630C01
2.167,3.25 2,3.25 2,3.25 1.479,1.594 true 0.25,0.427 0.625,0.667 0.375,0.24 12 false *A 3.667,0.427 4.042,0.667 0.375,0.24 12 false *B 2.219,3.167 2.531,3.365 0.313,0.198 10 false *a
*A for BOSCH Made *B except BOSCH Made
*a Mark - -



PROCEDURE

Hide 29300 1.INSTALL VACUUM PUMP ASSEMBLY

a.
C452308C02
5.115,0.74 5.365,0.323 5.365,0.323 5.531,0.323 true 5.427,1.563 5.594,1.563 5.594,1.563 5.844,1.042 true 5.198,1.469 5.385,1.646 0.188,0.177 10 true *a 5.573,0.229 5.781,0.417 0.208,0.188 10 true *b 0.917,0.115 1.198,0.469 0.281,0.354 18 false i 3.917,0.052 4.198,0.406 0.281,0.354 18 false ii 2.542,2.052 2.792,2.323 0.25,0.271 18 true iii 4.125,3.313 4.313,3.49 0.188,0.177 10 true A 2.719,3 2.906,3.177 0.188,0.177 10 true B 2.646,2.74 2.833,2.917 0.188,0.177 10 true B
*a Coupling Teeth *b Groove
V113147

Install in this Direction - -


i.

When reusing the vacuum pump assembly:

Install a new No. 1 vacuum pump O-ring to the vacuum pump assembly.


ii.

Install the vacuum pump assembly so that the coupling teeth of the vacuum pump assembly and groove of the camshaft are engaged.

NOTICE:
·

Ensure that the vacuum pump assembly is installed securely.

·

Be careful not to pinch the No. 1 vacuum pump O-ring.




iii.

Using an 8 mm socket wrench, install the vacuum pump assembly with the 3 bolts.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)

NOTICE:
·

Perform the procedure by fully tightening the bolt (A), and then fully tightening the bolts (B).

·

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





Hide 16575F 2.INSTALL NO. 3 WATER HOSE CLAMP BRACKET

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)

Hide 25719 3.INSTALL VACUUM SURGE TANK

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)

Hide 82121 4.INSTALL ENGINE WIRE

a.
C452310C01
0.323,0.063 0.604,0.417 0.281,0.354 18 false i 4.26,0.031 4.823,0.313 0.563,0.281 18 true ii, iii 0.229,2.063 0.552,2.333 0.323,0.271 18 false iv 3.698,2.031 4.021,2.302 0.323,0.271 18 false v 1.552,4.021 2.292,4.323 0.74,0.302 18 false vi, vii
V113147

Connect the connector
V113148

Lock the lock lever


i.

Connect the connector.


ii.

Connect the connector and lock the lock lever.


iii.

Connect the connector and engage the clamp.


iv.

Connect the 6 connectors and engage the 2 clamps.


v.

Connect the 2 connectors and engage the clamp.


vi.

Connect the connector and engage the clamp.


vii.

Install the engine wire with the bolt and 2 nuts.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)



Hide 44777 5.CONNECT NO. 1 VACUUM HOSE CONNECTOR

Z101186

NOTICE:
·

Check that there is no foreign matter on the connecting parts.

·

After connecting the No. 1 vacuum hose connector, check that the vacuum pump assembly and No. 1 vacuum hose connector are securely connected by pulling on them.




a.
C452311N01
1.76,0.063 2.042,0.417 0.281,0.354 18 false i

i.

Align the No. 1 vacuum hose connector with the vacuum pump assembly, and push them together until the No. 1 vacuum hose connector makes a "click" sound.