Removal and installation of the brake booster servo vacuum pump (diesel models)

Removing

1. On models with 1.7 l engines the vacuum pump is mounted on the back of the generator. On engines 2.0 l the vacuum pump is mounted on the left side of the cylinder head. Access to the pump models 1.7 l can be achieved by removing the heat shield of the header pipe, or by dismantling the generator (see chapter Engine electrical equipment).

The location of the vacuum pump on the model 1.7 l



2. On models 1.7 l apply the parking brake, jack up the front of the vehicle and place it on jack stands. If equipped, remove the crankcase protection.

3. On 2.0 l models in order to gain access, loosen the clamps and remove the intake ducts and the hose leading from the turbine to the intercooler. Disconnect the small vacuum hose from the bottom of the vacuum pump, remove the bolts from the two lifting eyes of the power unit on the left side of the cylinder head. Release the fuel pipes from the support brackets and move the electrical wiring routing chute with the bracket down from the vacuum pump.

4. Disconnect the amplifier vacuum tube from the pump, holding the large nut of the union connector, release the small one - on some models, a quick docking connector is used (2).




5. On models 1.7 l Loosen the union nut and disconnect the oil supply pipe from the pump. Also disconnect the oil return pipe, drain the oil into the prepared container. Seal the openings immediately to prevent dirt from entering the system.

6. Remove the mounting bolts, - pay attention to the support brackets fixed by them, - and remove the pump from the generator splines (engine 1.7 l) or from cylinder head (engine 2.0 l).

7. Remove the O-ring from the generator (engine 1.7 l), or pump grooves (engine 2.0 l), - the ring must be replaced without fail. On engines 1.7 l, if necessary, mark the plate inside the pump body, remove the plate and gasket.

Installation

Installation is in the reverse order. Pay attention to the following points.

1. On 1.7L models, before installing the pump, pour approximately 5 ml of clean engine oil into the hole for installing the oil feed pipe.

2. Clear interfaced surfaces and establish a new sealing ring.

3. On 1.7L models, by installing the pump on the generator, manually check the freedom of its rotation.