WATER PUMP REMOVAL


  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)


    1. Start up the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible.

    4. Stop the engine.

    5. Using SST, let the refrigerant gas out.

      SST
      07110-58060   ( 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080 )

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE NO. 1 ENGINE UNDER COVER (for Cold Area Specification Vehicles)


    1. Remove the 4 bolts and No. 1 engine under cover.

  4. DRAIN ENGINE COOLANT

    A01BDM5E01

    CAUTION:

    To avoid the danger of being burned, do not remove the reservoir cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.


    1. Loosen the radiator drain plug.

    2. Remove the reservoir cap.

    3. Loosen the cylinder block drain plug (on the engine oil cooler cover), and drain the coolant.

    4. Tighten the radiator drain plug.

    5. Tighten the cylinder block drain plug (on the engine oil cooler cover).

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  5. REMOVE FRONT DOOR SCUFF PLATE RH


    1. Disengage the 5 clips and remove the front door scuff plate RH.

  6. REMOVE FRONT SEAT ASSEMBLY RH


    1. A01BBC8

      Move the front seat assembly fully forward.

    2. Remove the 2 bolts on the rear side of the seat.

    3. Move the front seat assembly to the rearmost position.

    4. Remove the 2 bolts on the front side of the seat.

    5. Move the front seat assembly to the center of the seat slide rail. Set the seatback in the upright position.

    6. Disconnect the front seat inner belt assembly connector.

    7. Remove the front seat assembly.

  7. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Roll up the carpet and remove the engine service hole sub cover.

  8. REMOVE NO. 2 ENGINE SERVICE HOLE COVER


    1. Detach the clips and fold back the carpet.

    2. A01BD0S

      Remove the 3 bolts and No. 2 engine service hole cover.

  9. REMOVE FENDER APRON MUDGUARD SEAL RH


    1. Disengage the 3 clips and remove the fender apron mudguard seal RH.

  10. REMOVE NO. 1 RADIATOR HOSE

  11. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A01BE75

      Remove the 2 bolts and disconnect the vane pump oil reservoir.

  12. LOOSEN FAN PULLEY


    1. Loosen the 4 nuts from the fan pulley.

  13. REMOVE FAN AND GENERATOR V BELT


    1. A01BERGE01

      Remove the drive belt by rotating the tensioner pulley clockwise to loosen its tension with the pulley set bolt of the tensioner.

  14. REMOVE FAN PULLEY


    1. Remove the 4 nuts and fan pulley.

  15. DISCONNECT NO. 1 AIR CLEANER HOSE


    1. A01BHN9

      Pull the stopper upward and disconnect the No. 1 air cleaner hose from the compressor inlet elbow.

  16. REMOVE AIR TUBE ASSEMBLY


    1. A01BHAO

      Loosen the 2 hose clamps.

    2. Remove the 2 bolts, air tube and No. 1 air cleaner hose.

  17. REMOVE COMPRESSOR ELBOW STAY


    1. A01BF8X

      Remove the 2 bolts and compressor elbow stay.

  18. REMOVE COMPRESSOR OUTLET ELBOW


    1. A01BFP8

      Loosen the 2 hose clamps and remove the bolt and compressor outlet elbow.

  19. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (w/ Air Conditioning System)


    1. A01BGYM

      Remove the bolt and disconnect the cooler refrigerant discharge hose from the compressor and magnetic clutch.

    2. Remove the O-ring from the cooler refrigerant discharge hose.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  20. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (w/ Air Conditioning System)


    1. A01BDO5

      Remove the bolt and disconnect the cooler refrigerant suction hose.

    2. Remove the O-ring from the cooler refrigerant suction hose.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  21. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)


    1. Disconnect the connector.

    2. A01BFJ0

      Remove the 4 bolts and compressor and magnetic clutch.

  22. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


    1. A01BFLCE01

      Remove the 4 bolts and No. 1 compressor mounting bracket.

  23. REMOVE NO. 2 IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. Remove the bolt, pulley plate, No. 2 idle pulley and spacer.

  24. REMOVE GENERATOR BRACKET


    1. A01BCXBE01

      Remove the 2 bolts, then remove the generator bracket.

  25. REMOVE GENERATOR ASSEMBLY


    1. A01BCVDE01

      Disconnect the generator connector.

    2. Remove the terminal cap.

    3. Remove the nut and disconnect the wire harness from terminal B.

    4. Remove the bolt and generator.

  26. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01BDED

      Remove the 4 bolts and V-ribbed belt tensioner.

  27. REMOVE NO. 1 TIMING BELT COVER


    1. Remove the wire harness clamp.

    2. A01BDL8

      Remove the 6 bolts and timing belt cover.

  28. REMOVE TIMING BELT


    1. A01BB9ZE03

      Set the No. 1 cylinder to TDC/ compression.


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

        Tech Tips

        If reusing the timing belt, draw a direction arrow on the belt (in the direction of engine revolution) and place matchmarks on the pulleys and belt as shown in the illustration.

    2. A01BHFHE01

      Alternately loosen the 2 bolts, and remove the timing belt tensioner.

    3. A01BFILE02

      Remove the timing belt.

      Tech Tips


      • When turning the camshaft with the timing belt removed, first turn the crankshaft 90° counterclockwise to lower the piston.

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

  29. REMOVE NO. 4 AIR HOSE (w/ DPF)


    1. A01BGDR

      Loosen the 2 hose clamps.

    2. Remove the No. 4 air hose.

  30. REMOVE DIESEL THROTTLE BODY ASSEMBLY (w/ DPF)


    1. w/o DPF:


      1. A01BAQ0

        Disconnect the diesel turbo pressure sensor connector and vacuum switching valve connector.

      2. Remove the bolt and disconnect the wire harness clamp.

    2. Disconnect the 2 diesel throttle body connectors.

    3. A01BB1VE01

      Remove the 2 bolts, 2 nuts, diesel throttle body and gasket.

  31. DISCONNECT ENGINE WIRE (w/ DPF)


    1. A01BH3F

      Detach the 3 clamps and disconnect the water by-pass hose and oil return hose.

    2. A01BF0O

      Detach the clamp and disconnect the glow plug connector.

    3. Disconnect the 7 connectors.

    4. Remove the 7 bolts and disconnect the engine wire.

      A01BDFJ

    5. Disconnect the 4 connectors and detach the 3 clamps.

    6. Remove the terminal cap.

    7. Remove the nut and disconnect the wire harness from terminal B.

    8. Remove the bolt and disconnect the engine wire.

      A01BGIGE01

    9. Fold back the floor carpet.

    10. Disconnect the 6 ECM connectors.

    11. A01BEK4

      Remove the bolt.

    12. A01BCV8

      Disconnect the 3 connectors.

  32. REMOVE INJECTION PIPE SUB-ASSEMBLY (w/ DPF)


    1. A01BAC9

      Remove the 3 bolts and 3 No. 2 injection pipe clamps.

    2. A01BEYL

      Using a 17 mm union nut wrench, loosen the union nuts and remove the 4 injection pipes.

  33. REMOVE VACUUM CONTROL VALVE SET (w/ DPF)


    1. A01BBW7

      Disconnect the vacuum control valve connector and 2 vacuum hoses.

    2. Remove the bolt and vacuum control valve set.

  34. DISCONNECT NO. 5 WATER BY-PASS HOSE (w/ DPF)

    A01BEFN

  35. REMOVE FUEL INLET PIPE SUB-ASSEMBLY (w/ DPF)

    Note

    If a No. 1 injection pipe clamp is removed from the fuel inlet pipe, replace the No. 1 injection pipe clamp with a new one.


    1. A01BFWK

      Remove the 2 bolts and 2 No. 1 injection pipe clamps.

    2. Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

  36. REMOVE COMMON RAIL ASSEMBLY (w/ DPF)


    1. A01BFXR

      Remove the 2 bolts and common rail.

      Note

      Do not remove the pressure discharge valve or fuel pressure sensor.

  37. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR (w/ DPF)

    A01BHU8

  38. REMOVE NO. 1 CYLINDER HEAD COVER SILENCER (w/ DPF)


    1. A01BH9R

      Remove the No. 1 cylinder head cover silencer from the cylinder head cover.

  39. REMOVE INJECTION PIPE SUB-ASSEMBLY (w/o DPF)


    1. A01BHX7

      Disconnect the 4 injector connectors.

    2. Remove the 4 bolts and detach the 3 clamps.

    3. A01BEJA

      Remove the 2 bolts and 2 No. 2 injection pipe clamps.

    4. A01BFN0

      Using a 17 mm union nut wrench, loosen the union nuts and remove the 4 injection pipes.

  40. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01BDCBJ01

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

    2. Disconnect the ventilation hose.

    3. A01BGDA

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

    4. A01BGWS

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

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


    1. A01BH1YE01

      Using a 10 mm hexagon wrench, remove the bolt, No. 1 timing belt idler and washer.

  42. REMOVE CAMSHAFT TIMING PULLEY


    1. A01BBTF

      Remove the bolt and camshaft timing pulley while holding the camshaft with a wrench.

    2. A01BDDQE01

      Using SST, remove the camshaft timing pulley and set key.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-05010, 09957-04010 )
      09955-04150
    3. A01BFILE02

      Rotate the crankshaft approximately 90° counterclockwise from TDC to lower the piston.

  43. REMOVE NO. 2 TIMING BELT COVER


    1. A01BC0NE01

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

  44. REMOVE WATER PUMP ASSEMBLY


    1. A01BCAP

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