WATER PUMP REMOVAL


  1. DISCONNECT BATTERY NEGATIVE CABLE

  2. REMOVE ENGINE UNDER COVER NO.1

  3. REMOVE FRONT DOOR SCUFF PLATE RH

  4. REMOVE FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)

    Click here

    Tech Tips

    Perform the same procedure as RH side on the LH side.

  5. REMOVE FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)

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    Tech Tips

    Perform the same procedure as RH side on the LH side.

  6. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


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

  7. REMOVE FENDER APRON MUDGUARD SEAL RH

  8. REMOVE FAN & GENERATOR V BELT


    1. A01BGLOE03

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

  9. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)


    1. Disconnect the connector.

    2. A01BFJ0

      Remove the 4 bolts and compressor and magnetic clutch.

  10. REMOVE AIR TUBE ASSEMBLY


    1. Remove the 2 clamps, 2 bolts and air tube assembly.

  11. REMOVE AIR CLEANER HOSE ASSEMBLY


    1. Remove the bolt and air cleaner hose assembly.

  12. REMOVE COMPRESSOR OUTLET ELBOW


    1. A01BCJB

      Remove the 2 bolts and 2 clamps, then remove the compressor outlet elbow.

  13. REMOVE IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. A01BETHE01

      Remove the bolt and washer, then remove the idle No.2 pulley assembly.

  14. REMOVE GENERATOR BRACKET


    1. A01BCXBE01

      Remove the 2 bolts, then remove the generator bracket.

  15. 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 assembly.

  16. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. Remove the 4 bolts and belt tensioner assembly.

  17. REMOVE FAN PULLEY


    1. Remove the 4 nuts, 4 washer and fan pulley.

  18. REMOVE TIMING BELT COVER NO.1


    1. Remove the wire harness clamp.

    2. A01BHT6

      Remove the 6 bolts and timing belt cover No.1.

  19. REMOVE TIMING BELT


    1. A01BB9ZE01

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

    2. A01BHFH

      Uniformly loosen the 2 bolts, and remove the chain tensioner assembly No.1.

    3. Remove the timing belt.

  20. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A01BBC4E01

      Remove the 2 bolts and vane pump oil reservoir assembly.

      Note

      Suspend the vane pump oil reservoir assembly with wire to prevent power steering fluid from spilling out.

  21. DISCONNECT OIL RETURN HOSE (w/ Intercooler)

  22. REMOVE EGR PIPE SUB-ASSEMBLY NO.1 (w/ EGR Valve)


    1. A01BGWP

      Disconnect the fuel pressure sensor connector.

    2. A01BD88

      Remove the 2 bolts, 2 nuts, and the EGR pipe sub-assembly.

    3. Remove the 2 gaskets.

  23. REMOVE AIR HOSE NO.4


    1. A01BGX6

      Loosen the 2 clamps.

    2. Remove the air hose No.4.

  24. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A01BCMO

      Disconnect the 2 throttle body connectors.

    2. A01BBJH

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

    3. Remove the gasket from intake air connector.

  25. REMOVE ENGINE SERVICE HOLE COVER NO.2


    1. A01BG4E

      Roll up the carpet.

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

  26. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR Valve)


    1. Remove the vacuum regulating valve.


      1. A01BHSL

        Remove the 2 vacuum hoses and the vacuum regulating valve connector.

      2. Remove the 2 bolts and the vacuum regulating valve.

    2. Remove the EGR valve assembly with the sensor.


      1. A01BCF1

        Remove the bolt, and separate the manifold stay.

      2. Disconnect the vacuum hose from the intake air connector.

      3. A01BAPE

        Disconnect the intake air temperature sensor connector.

      4. Disconnect the EGR valve position sensor connector.

      5. A01BACYE01

        Remove the bolt, 2 nuts and the intake air connector assembly.

      6. Remove the 2 gaskets and EGR valve assembly from the intake air connector.

  27. REMOVE INTAKE AIR CONNECTOR (w/o EGR Valve)


    1. A01BDK1

      Remove the bolt, and separate the manifold stay.

    2. Disconnect the vacuum hose from intake air connector.

    3. A01BEP8E01

      Remove the bolt, 2 nuts and the intake air connector assembly.

    4. Remove the 2 gaskets and intake air connector No.2 from the intake air connector.

  28. REMOVE OIL LEVEL GAGE GUIDE


    1. Remove the oil level gauge.

    2. Remove the bolt and oil level gauge guide.

  29. REMOVE INJECTION PIPE

    SST
    09023-12701

    1. Remove the injection pipe.


      1. A01BC89

        Remove the 2 nuts and injection pipe clamp No.3.

      2. A01BFG2

        Using SST, remove the 4 injection pipes.

        SST
        09023-12701

  30. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. Using SST, remove the fuel inlet pipe sub-assembly.

      SST
      09023-12701

  31. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01BAID

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

    2. Disconnect the ventilation hose.

    3. A01BF0S

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

      Note

      After removing the fuel pipe, put a plastic bag and rubber band to prevent dirt and foreign objects over the injectors inlet.

    4. A01BGWS

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

  32. REMOVE CAMSHAFT TIMING PULLEY


    1. A01BHHN

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

    2. A01BDDQE01

      Using SST, remove the camshaft timing pulley.

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

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


    1. A01BH1Y

      Using a 10 mm socket hexagonal wrench remove the timing belt idler No.1.

  34. REMOVE TIMING BELT COVER NO.2


    1. A01BCA8

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

  35. REMOVE WATER PUMP ASSEMBLY


    1. A01BCAP

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