WATER PUMP REMOVAL

REMOVE FAN AND GENERATOR V BELT

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REMOVE NO. 1 ENGINE COVER
1. Hold the rear of the cover and slowly raise it to detach the clip on the rear of the cover. Continue to raise the cover to detach the 3 clips on the front and side of the cover and remove the cover.
  
  Note
  
  Attempting to disengage both front and rear clips at the same time may cause the cover to break.
REMOVE RADIATOR SUPPORT OPENING COVER
1. Remove the 6 clips and radiator support opening cover.

DRAIN ENGINE COOLANT

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.
Remove the radiator reservoir cap.

CAUTION:

Do not remove the radiator reservoir cap and air release plug, while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

Loosen the cylinder block drain cock plug. Then drain the coolant from the engine.

Tech Tips

The plug is on the backside of the generator on the EGR cooler side.

Text in Illustration
*1	Radiator Reservoir Cap	*2	Air Release Plug
*3	Cylinder Block Drain Cock Plug (Type A)	*4	Cylinder Block Drain Cock Plug (Type B)
*5	Radiator Drain Cock Plug	-	-

DISCONNECT NO. 1 WATER BY-PASS HOSE
1. Disconnect the No. 1 water by-pass hose.
REMOVE IDLER PULLEY COVER PLATE
1. Text in Illustration
  
  *1 Tape
  
  Using a screwdriver, remove the idler pulley cover plate.
  
  Tech Tips
  
  Tape the screwdriver tip before use.
REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY
1. Remove the bolt and No. 1 idler pulley.

Text in Illustration
*1	Tape

REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY

Text in Illustration
*1	No. 2 Idler Pulley Cover Plate
*2	No. 2 Idler Pulley

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

REMOVE WATER PUMP ASSEMBLY
1. Remove the 7 bolts, water pump assembly and gasket.