WATER PUMP (w/o DPF) REMOVAL


  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


    1. Remove the 13 clips and upper radiator support seal.

  3. REMOVE FRONT BUMPER LOWER COVER


    1. Remove the clip, 5 bolts and front bumper lower cover.

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


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

  5. REMOVE ENGINE REAR UNDER COVER ASSEMBLY


    1. Remove the 4 bolts and rear engine under cover.

  6. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator 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. A00JWDE

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

    3. Loosen the cylinder block drain cock plug.

      A00JVX9E01
      Text in Illustration
      *1 Radiator Reservoir *2 Vent Plug
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug

  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)


    1. A00JUQI

      Remove the bolt and disconnect the inlet heater water hose.

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


    1. A00JWMM

      Remove the bolt and disconnect the No. 4 vacuum transmitting pipe.

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


    1. A00JZLQ

      Disconnect the 3 connectors from the intake air temperature sensor, throttle control motor and manifold absolute pressure sensor.

    2. Detach the 2 clamps.

    3. Disconnect the vacuum hose from the manifold absolute pressure sensor.

    4. A00JWSR

      Loosen the 2 hose clamps of the No. 1 air hose.

    5. A00JV3H

      Loosen the hose clamp of the intercooler air hose.

    6. A00K23L

      Remove the 2 bolts and No. 1 intake pipe.

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


    1. A00OA28

      Disconnect the vacuum hose.

    2. Remove the bolt and gas filter with gas filter bracket.

    3. Remove the 2 bolts and throttle body bracket.

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

    Note


    • After removing the injection pipe, cover the outlets on the common rail with tape to keep out foreign matter.

    • After removing the injection pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.


    1. A00XH0D

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

    2. A00XH1Z

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

    3. A00XJETE01
      Text in Illustration
      *a Injector Side
      *b Common Rail Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

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


    1. A00O30T

      Remove the 3 bolts and air connector stay.

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


    1. A00O8HT

      for LHD:

      Remove the 2 bolts and disconnect the clamp and engine wire.

    2. A00OA2U

      for RHD:

      Remove the bolt and disconnect the engine wire.

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


    1. A00O7OP

      Disconnect the throttle position sensor connector.

    2. A00O5VW

      Remove the 3 bolts, intake air connector with diesel throttle and gasket.

  16. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. Disconnect the vacuum switching valve connector.


      1. A00O5P2

        w/o EGR System:

        Disconnect the connector.

      2. A00O70W

        w/ EGR System without EGR Cooler:

        Disconnect the 2 connectors.

      3. A00O5WE

        w/ EGR System with EGR Cooler:

        Disconnect the 3 connectors.

    2. A00O3VL

      Disconnect the No. 1 vacuum transmitting hose.

    3. A00OB6W

      w/ EGR System:

      Disconnect the No. 2 vacuum transmitting hose and No. 3 vacuum transmitting hose.

    4. A00OAHN

      w/ EGR Cooler:

      Disconnect the No. 3 vacuum transmitting hose.

    5. A00O4FYE03
      Text in Illustration
      *A w/o EGR System
      *B w/ EGR System

      Disconnect the No. 3 vacuum transmitting hose and No. 4 vacuum transmitting hose.

    6. A00O5B8

      Remove the 2 bolts and manifold stay with vacuum switching valve.

  17. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A00XF0Y

      Remove the bolt and detach the injection pipe clamp.

      Note

      If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.

    2. A00XHHME06
      Text in Illustration
      *a Injector Side
      *b Common Rail Side

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

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


    1. A00XHHE

      Disconnect the 4 injector connectors.

    2. Detach the 2 wire harness clamps and disconnect the wire harness from the No. 2 cylinder head cover.

    3. A00XENP

      Remove the 4 bolts and No. 2 cylinder head cover.

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


    1. A0098I9

      Remove the 2 bolts and front heater bracket.

  20. REMOVE NO. 1 RADIATOR HOSE

    A00O4GN

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


    1. A00O74S

      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. A00OADW

      Loosen the 2 clamps.

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

  23. REMOVE INTERCOOLER AIR HOSE


    1. A00O34C

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

    2. A00OBD1

      Loosen the 2 clamps.

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

  24. REMOVE FAN SHROUD


    1. A00O3CJ

      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. A00O6YT

        Disconnect the 2 oil cooler hoses from the radiator.

    5. A00O5ZQ

      Loosen the 4 nuts holding the fluid coupling and fan.

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

    7. A00O6LU

      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. A00O6JL

      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


    1. A00O6QW

      Loosen the 2 hose clamps and remove the No. 1 air cleaner hose.

  26. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    A00O8YJE01
    Text in Illustration
    *A except Cold Area Specification Vehicles
    *B for Cold Area Specification Vehicles

    1. except Cold Area Specification Vehicles:

      Detach the 2 clamps and disconnect the mass air flow meter connector.

    2. for Cold Area Specification Vehicles:

      Detach the 3 clamps and disconnect the mass air flow meter connector.

    3. Detach the 4 clamps and remove the air cleaner cap.

  27. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  28. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A00O7C8

      Remove the 3 bolts and air cleaner case.

  29. REMOVE COMPRESSOR OUTLET ELBOW


    1. A00O90M

      Detach the 3 wire harness clamps.

    2. Remove the bolt and wire harness bracket.

    3. A00O4RO

      Loosen the hose clamp and remove the 2 bolts and compressor outlet elbow.

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


    1. Disconnect the viscous heater connector.

    2. A00O4ER

      Disconnect the water by-pass hose and water hose.

    3. A00O4BR

      Remove the 2 bolts and viscous heater with magnet clutch.

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


    1. A00O4PQ

      Remove the 4 bolts and No. 1 viscous heater bracket.

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


    1. A00OAI3

      Disconnect the compressor connector.

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

  33. REMOVE GENERATOR BRACKET


    1. A00JWMI

      Remove the bolt and generator bracket.

  34. REMOVE GENERATOR ASSEMBLY


    1. A00JWKJ

      Disconnect the generator connector.

    2. Remove the terminal cap.

    3. Remove the nut and disconnect the generator wire.

    4. Remove the 2 bolts and generator.

  35. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A00K11Y

      Remove the 5 bolts and No. 1 compressor mounting bracket.

  36. REMOVE VENTILATION PIPE


    1. A00O8AJ

      Remove the bolt and disconnect the 2 ventilation hoses and ventilation pipe.

  37. 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. A00XD84E01

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

    2. A00XH2E

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

    3. A00XCKH

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

  38. REMOVE NO. 1 TIMING BELT COVER


    1. A0094PCE01

      Remove the 6 bolts, 6 washers and timing belt cover.

  39. REMOVE TIMING BELT


    1. A0098L2E05
      Text in Illustration
      *1 Timing Mark

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

      Tech Tips

      If reusing the timing belt, place matchmarks on the timing belt so that it can be installed exactly as before.

    2. A00960LE01

      Uniformly loosen and remove the 2 bolts and No. 1 timing belt tensioner.

    3. Remove the timing belt.

      Tech Tips

      A0098I0E02

      • If turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.

      • When installing the timing belt, turn the camshaft to align the timing marks and then turn the crankshaft clockwise to align the timing marks.

  40. REMOVE CAMSHAFT TIMING PULLEY


    1. A00XEISE01

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

      Note

      Make sure the timing belt is not installed when removing the bolt of camshaft timing pulley.

    2. Remove the camshaft timing pulley.

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

    Note

    When inspecting the No. 1 timing belt idler, do not remove it unless absolutely necessary.


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

  42. REMOVE NO. 2 TIMING BELT COVER


    1. A00XDLI

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

  43. REMOVE CYLINDER BLOCK INSULATOR


    1. A00XC1L

      Remove the cylinder block insulator from the cylinder head.

  44. REMOVE WATER PUMP ASSEMBLY


    1. A00O70H

      Remove the 2 nuts, 6 bolts, water pump and gasket.

  45. REPLACE STUD BOLT

    Tech Tips

    If a stud bolt is deformed or its threads are damaged, replace it.


    1. A00O6TX

      Remove the stud bolts.

    2. Install the stud bolts.

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

  46. REPLACE RING PIN

    Tech Tips

    It is not necessary to remove a ring pin unless it is being replaced.


    1. A00O3CR

      Remove the ring pin.

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