WATER PUMP REMOVAL


  1. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. A01FIO6E01

      Place one hand on the rear of the cover as shown in the illustration and detach the clip near the rear. Then, place both hands on the sides of the cover and lift the cover to detach the 2 clips near the front in the order shown in the illustration to remove the cover.

      Text in Illustration
      A01FE8R Areas to place hands when lifting cover

      Note

      If the cover is lifted rearward or forward and to the right or left at the same time, the cover maybe damaged.

  2. REMOVE ENGINE ROOM SIDE COVER


    1. A01FGMK

      Remove the 4 clips and engine room side cover.

  3. REMOVE COOL AIR INTAKE DUCT SEAL


    1. A01FGF0

      Remove the 7 clips and cool air intake duct seal.

  4. REMOVE NO. 1 AIR CLEANER INLET


    1. A01FHG8

      Remove the bolt and No. 1 air cleaner inlet.

  5. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start the engine.

    2. Operate the cooler compressor under the conditions shown below:

      Item Condition
      Engine Speed Idling
      Operating Time 3 minutes or more
      A/C Switch Status On
      Blower Switch Status HI
      Set Temperature MAX COOL

      This causes most of the compressor oil from the various components of the A/C system to collect in the A/C compressor.

      Note

      It is not necessary to operate the cooler compressor if the A/C does not operate because of compressor lock, etc.

    3. Stop the engine.

    4. Recover the refrigerant from the A/C system using a refrigerant recovery unit.

      Tech Tips

      Use the refrigerant recovery unit in accordance with the manufacturer's instruction manual.

  6. DRAIN ENGINE COOLANT


    1. Loosen the radiator drain cock plug and drain the coolant.

      A01FIVGE02
      Text in Illustration
      *1 Radiator Cap *2 Radiator Drain Cock Plug
      *3 Cylinder Block Drain Cock Plug *4 Radiator Reservoir Tank

      CAUTION:

      Do not remove the radiator cap, cylinder block drain cock plugs and radiator drain cock plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

      Tech Tips

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

    2. Remove the radiator cap.

    3. Loosen the 2 cylinder block drain cock plugs.

  7. REMOVE FAN AND GENERATOR V BELT


    1. A01FIUU

      While releasing the belt tension by turning the belt tensioner counterclockwise, remove the V belt from the belt tensioner.

    2. A01FHWGE01

      While turning the belt tensioner counterclockwise, align its holes, and then insert the 5 mm bi-hexagon wrench into the holes to secure the belt tensioner.

  8. REMOVE ENGINE UNDER COVER


    1. A01FF39

      Remove the 13 screws, 3 clips and engine under cover.

  9. REMOVE REAR ENGINE UNDER COVER LH


    1. A01FH08

      Remove the screw and rear engine under cover LH.

  10. DISCONNECT SUCTION HOSE

    A01FFPG

    1. Remove the bolt and disconnect the suction hose from the cooler compressor assembly.

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

      Note

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

  11. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    A01FIQH

    1. Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the cooler compressor assembly.

    2. Remove the O-ring from the No. 1 cooler refrigerant discharge hose.

      Note

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

  12. REMOVE COOLER COMPRESSOR ASSEMBLY


    1. Disconnect the connector.

    2. A01FE74

      Remove the 3 bolts and nut.

    3. A01FHU3

      Using an E8 "torx" socket, remove the stud bolt and cooler compressor assembly.

  13. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01FHP4

      Remove the 5 bolts, then remove the V-ribbed belt tensioner assembly.

  14. REMOVE NO. 1 RADIATOR HOSE


    1. A01FEGM

      Remove the No. 1 radiator hose.

  15. DISCONNECT NO. 2 RADIATOR HOSE


    1. A01FHKX

      Disconnect the No. 2 radiator hose from the water inlet with thermostat sub-assembly.

  16. REMOVE NO. 1 ENGINE COVER


    1. A01FIZP

      Remove the 3 clips and No. 1 engine cover.

  17. REMOVE INJECTOR DRIVER


    1. A01FEVIE02
      Text in Illustration
      *1 Lock Lever
      *a Release
      *b Lock with Connector

      Move the lock levers in the direction indicated by the arrow to release the 3 connector locks. Disconnect the 4 connectors from the injector driver.

    2. A01FE1B

      Remove the bolt, 2 nuts and injector driver.

      Note

      Be careful not to drop or strike the injector driver.

  18. REMOVE NO. 2 ENGINE COVER


    1. A01FH26

      Remove the 3 clips and clamp, then remove the No. 2 engine cover.

  19. REMOVE WATER PUMP PULLEY


    1. A01FHMUE03

      Using SST, hold the water pump pulley.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

    2. Remove the 4 bolts and water pump pulley.

  20. REMOVE WATER INLET ASSEMBLY


    1. A01FIEP

      Disconnect the 5 hoses.

    2. A01FF2ZE02

      Remove the 4 bolts, nut and water inlet assembly.

      Text in Illustration
      A01FGIV Bolt
      A01FJ4N Nut
    3. A01FEPTE03
      Text in Illustration
      *1 No. 1 Water Inlet Housing Gasket
      *2 Water Outlet Pipe O-ring

      Remove the No. 1 water inlet housing gasket and water outlet pipe O-ring.

  21. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A01FFAA

      Remove the bolt, No. 2 idler pulley cover plate and No. 2 idler pulley sub-assembly.

  22. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01FGA9

      Remove the 16 bolts, engine water pump assembly and water pump gasket.