ATTENTION: Refer to the appropriate vehicle manufacturer´s service / repair manual for your vehicle to obtain specific service procedures for this part. If you do not have a service manual or if you lack the skill or you do not have the necessary tools to install / repair this part, it is recommended that you seek the services of a qualified vehicle technician. Pay special attention to all cautions and warnings included in the manufacturer´s service manual and follow any applicable regulatory requirements. Read and follow all of the vehicle manufactures instructions carefully. The following repair guide instructions have been written as a supplement to (i.e. not designed to replace) the specific vehicle manufactures service manual. We have made every effort to ensure that the instructions are accurate; however, we assume no liability for any inaccuracies or omissions. If you find any information in this repair guide that is incorrect or incomplete, we would appreciate your feedback. Note: By design the new cup seal is slightly thicker than the original seal and needs to be compressed equally & evenly at all four compression points (three screws and one mounting bolt).
Tools & accessories needed:
a) M8 Bolt, Nut & washer, bolt length should be 40mm or more.
b) Torx T20 driver.
c) Large ¾" square drive socket (to support vacuum pump when reassembling)
d) A small amount of engine oil
Important Numbers:
7.28237.04 00
GM 55 561 099
16 T 152 / 1507
7.28237.02 C
GM 12 787 696
04 T 315 / 3321
1) Before removing the vacuum pump from the engine, release the three T20 Torx screws that attach the vacuum actuator to the flange of the vacuum pump.
2) Following the vehicle manufacturers instructions, remove the complete vacuum pump assembly from the cylinder head.
3) Prise off and discard the old black rubber flange gasket (pump to the cylinder head).
4) Remove the three Torx T20 screws holding the vacuum actuator on the flange of the vacuum pump.
5) Remove and discard the old grey seal from the recess in the flange of the vacuum pump.
6) Remove the two shoes, the sliding vane and the central shaft. Clean all components and check the condition of all of the rotating parts and surfaces (including the inside surface of the vacuum chamber) for uneven or excessive score / wear marks. If such marks can be found, the vacuum pump should be replaced rather than repaired.
7) Clean the groove for the old vacuum actuator seal and the sealing lip of the vacuum actuator.
8) Clean all of the oil channels (including the metal gauze filter) in the body of the vacuum pump. Any blockages / restrictions to the oil flow will shorten the life of the vacuum pump.
9) Fit the new FPM Vacuum Cup seal.
10) Use new engine oil, lubricate all rotating parts and sliding surfaces. Also lubricate the inside of the vacuum actuator.
11) Reassemble the central shaft, the sliding vane and the two end shoes (as shown in the photo aboce) and support the vacuum pump with the ¾" square drive socket.
12) Refit the vacuum actuator ensuring that the two shoes remain attached to each end of the sliding vane.
13) Whilst holding the vacuum actuator in place, insert the three T20 Torx screws and loosely hand tighten each of them.
14) Temporarily insert an M8 bolt, washer and nut through the mounting hole that secures the vacuum actuator onto the flange of the vacuum pump.
15) Working in a clockwise or anti clockwise direction, tighten each screw or bolt a half of a turn at a time. Repeat until all screws and the bolt are fully tightened. This technique will ensure that the vacuum actuator sits absolutely perpendicular to the body of the pump and will prevent the shoes on the end of the sliding vane from "binding" on the inside of the Vacuum Cup.
16) When fully tightened, rotate the shaft of the vacuum pump by hand and check that there are no binding points. If found, go back to step 4 and repeat.
17) Remove the M8 bolt, fit a new flange gasket and refit the vacuum pump to the cylinder head in accordance with the vehicle manufacturers instructions.
18) Fully tighten the three T20 Torx screws.
19) Before driving the car, check that with the engine running that the vacuum pump generates the correct vacuum to the specification of vehicle manufacturer and that the brake system of the car works correctly. Check that there are no engine oil leaks from the vacuum pump.