WATER PUMP REMOVAL

PROCEDURE


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note


    • After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

    • When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  2. REMOVE UPPER RADIATOR SUPPORT SEAL

    Click here

  3. REMOVE FRONT BUMPER LOWER COVER

    Click here

  4. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

    Click here

  5. REMOVE ENGINE REAR UNDER COVER ASSEMBLY

    Click here

  6. DRAIN ENGINE COOLANT

    Click here

  7. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System)


    1. Remove the electric EGR control valve assembly Click here.

  8. DISCONNECT INLET HEATER WATER HOSE (w/o EGR System)

    Click here

  9. DISCONNECT NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/o EGR System)

    Click here

  10. REMOVE NO. 1 INTAKE PIPE (w/o EGR System)

    Click here

  11. REMOVE THROTTLE BODY BRACKET (w/o EGR System)

    Click here

  12. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE (w/o EGR System)

    Click here

  13. REMOVE AIR CONNECTOR STAY (w/o EGR System)

    Click here

  14. DISCONNECT ENGINE WIRE (w/o EGR System)

    Click here

  15. REMOVE INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/o EGR System)

    Click here

  16. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE

    Click here

  17. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Click here

  18. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  19. REMOVE FRONT HEATER BRACKET (for Cold Area Specification Vehicles)

    Click here

  20. REMOVE NO. 1 RADIATOR HOSE

    B001ESK

  21. REMOVE NO. 3 ENGINE WIRE (for Cold Area Specification Vehicles)


    1. B001E11

      Remove the 2 nuts from the battery terminal.

    2. Detach the 3 wire harness clamps.

    3. Remove the No. 3 engine wire from the fan shroud.

  22. REMOVE NO. 1 AIR HOSE


    1. B001I9N

      Loosen the 2 clamps.

    2. Remove the No. 1 air hose from the inlet pipe and intercooler.

  23. REMOVE INTERCOOLER AIR HOSE


    1. B001EJ8

      Disconnect the No. 2 vacuum transmitting hose from the intercooler.

    2. B001CG8

      Loosen the 2 clamps.

    3. Remove the intercooler hose from the intake pipe and intercooler.

  24. REMOVE FAN SHROUD


    1. B001DET

      Disconnect the No. 1 water by-pass hose and detach the 2 clamps from the fan shroud.

    2. Disconnect the No. 2 water by-pass hose from the radiator reservoir.

    3. Remove the 3 bolts and radiator reservoir.

    4. for Automatic Transmission:


      1. Remove the inlet and outlet oil cooler hoses and detach the clamp from the fan shroud.

      2. B001DUP

        Disconnect the 2 oil cooler hoses from the radiator.

    5. B001CD1

      Loosen the 4 nuts holding the fluid coupling and fan.

    6. Remove the fan and generator V belt Click here.

    7. B001FE2

      Remove the 2 bolts holding the fan shroud.

    8. Remove the 4 nuts for the fan with fluid coupling fan, and then remove the shroud together with the coupling fan.

      Note

      Be careful not to damage the radiator core.

    9. Detach the No. 2 water by-pass hose from the hose clamp on the fan shroud.

    10. B001D0Z

      Remove the No. 2 water by-pass hose from the water inlet.

    11. Remove the fan pulley from the water pump.

  25. REMOVE NO. 1 AIR CLEANER HOSE

    Click here

  26. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  27. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  28. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  29. REMOVE COMPRESSOR OUTLET ELBOW

    Click here

  30. REMOVE VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY (for Cold Area Specification Vehicles)

    Click here

  31. REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles)

    Click here

  32. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)

    Click here

  33. REMOVE GENERATOR BRACKET

    Click here

  34. REMOVE GENERATOR ASSEMBLY

    Click here

  35. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET

    Click here

  36. REMOVE VENTILATION PIPE

    Click here

  37. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  38. REMOVE NO. 1 TIMING BELT COVER

    Click here

  39. REMOVE TIMING BELT

    Click here

  40. REMOVE CAMSHAFT TIMING PULLEY

    Click here

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

    Click here

  42. REMOVE NO. 2 TIMING BELT COVER

    Click here

  43. REMOVE CYLINDER BLOCK INSULATOR

    Click here

  44. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. B001CL6

      Remove the 2 nuts, 5 bolts, engine water pump assembly and the gasket from the cylinder block sub-assembly.

    2. B001EI6

      Remove the bolt, water pump assembly without cover and the gasket from the water pump cover.

  45. REPLACE STUD BOLT

    Tech Tips

    Perform this procedure only when replacement of the stud bolts is necessary.


    1. B001IDD

      Remove the 4 stud bolts from the water pump assembly without cover.

    2. Install the 4 stud bolts to the water pump assembly without cover.

      Torque:
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }

  46. REPLACE WATER PUMP SET RING PIN

    Tech Tips

    Perform this procedure only when replacement of the water pump set ring pin is necessary.


    1. B001F9V

      Remove the water pump set ring pin from the water pump cover.

    2. Using a plastic-faced hammer, tap in the water pump set ring pin to the water pump cover.