WATER PUMP (w/ EGR Cooler) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

  2. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD)


    1. Remove the 4 bolts and cover.

  3. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. A01DY58E01

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    3. Loosen the cylinder block drain cock plug.

      A01E07NE01

  4. DISCONNECT RADIATOR HOSE INLET

  5. REMOVE FAN SHROUD

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    1. Remove the 3 bolts and oil reservoir.

    2. Disconnect the No. 1 and No. 2 water by-pass hoses from the tank upper and lower.

    3. Remove the 2 bolts and radiator reservoir.

    4. Loosen the 4 nuts holding the fluid coupling fan.

    5. Remove the drive belt Click here.

    6. Remove the 2 bolts holding the fan shroud.

    7. Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the coupling fan.

      Note

      Be careful not to damage the radiator core.

    8. Remove the fan pulley from the water pump.

  6. REMOVE COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


    1. Remove the 4 bolts and disconnect the cooler compressor.

      Tech Tips

      It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

  7. REMOVE GENERATOR ASSEMBLY

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    1. Remove the nut and generator wire.

    2. Disconnect the generator connector.

    3. Remove the 2 bolts and generator.

  8. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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    1. Remove the 4 bolts and V-ribbed belt tensioner.

  9. REMOVE EGR COOLER WITH ELECTRIC EGR CONTROL VALVE AND NO. 2 EGR VALVE


    1. Remove the EGR cooler Click here.

  10. REMOVE NO. 4 INJECTION PIPE


    1. A01E10I

      Remove the bolt and disconnect the injection pipe clamp.

    2. A01DVY2E02

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  11. REMOVE VENTILATION PIPE


    1. A01E0V8

      Remove the bolt and ventilation pipe.

  12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Note

    If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.


    1. A01E177

      Remove the 3 bolts and disconnect the 4 connectors.

    2. A01DXC5E01

      Using a small screwdriver, remove the holder seal by prying the portion between the holder seal and the cutout part of the cylinder head.

    3. Disconnect the ventilation hose.

    4. A01DZGHE01

      Remove the 10 bolts, 2 nuts, cylinder head cover and gasket.

    5. A01DV31

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.

  13. REMOVE NO. 1 TIMING BELT COVER

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    1. Remove the bolt and water hose clamp.

    2. Remove the wire harness clamp.

    3. Remove the 6 bolts and timing belt cover.

  14. REMOVE TIMING BELT

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    1. Turn the crankshaft clockwise and align the timing marks as shown in the illustration.

    2. A01E0E0E01

      Uniformly loosen the 2 bolts and remove the timing belt tensioner.

    3. Remove the timing belt.

    4. Using a 10 mm hexagon wrench, remove the bolt, timing belt idler and washer.

      Tech Tips

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      • When turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise.

      • When installing the timing belt, return the camshaft to the timing marks and then turn the crankshaft clockwise until it aligns with the timing marks, as shown in the illustration.

  15. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

  16. REMOVE CAMSHAFT TIMING PULLEY


    1. A01DV9RE01

      Remove the bolt of the camshaft timing pulley by holding the camshaft with a wrench.

      Note

      Make sure to remove the bolt of the camshaft timing pulley with the timing belt not installed.

    2. Remove the camshaft timing pulley.

  17. REMOVE NO. 2 TIMING BELT COVER


    1. Remove the 4 bolts, nuts and No. 2 timing belt cover.

  18. REMOVE CYLINDER BLOCK INSULATOR


    1. A01E2IC

      Remove the cylinder block insulator from the cylinder head.

  19. REMOVE WATER PUMP ASSEMBLY


    1. A01DWA8

      Remove the 2 nuts, 5 bolts, water pump and gasket.