WATER PUMP (w/ EGR Cooler) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

  2. REMOVE EGR COOLER WITH ELECTRIC EGR CONTROL VALVE AND NO. 2 EGR VALVE

    Click here

  3. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD)

  4. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir 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. A01DY58E01

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

    3. Loosen the cylinder block drain cock plug.

      A01E07NE01

  5. DISCONNECT RADIATOR HOSE INLET

  6. REMOVE FAN SHROUD

    A01DX5N

    1. Remove the 3 bolts and oil reservoir.

    2. Disconnect the No. 1 and No. 2 water by-pass hoses from the radiator tank upper and lower.

    3. Remove the 2 bolts and radiator reservoir.

    4. Loosen the 4 nuts holding the fluid coupling with fan.

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

    6. Remove the 2 bolts holding the fan shroud.

    7. Remove the 4 nuts of the fluid coupling with fan, and then remove the fan shroud together with the fluid coupling with fan.

      Note

      Be careful not to damage the radiator core.

    8. Remove the fan pulley from the engine water pump.

  7. REMOVE COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


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

      Tech Tips

      It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

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


    1. A01DZH8E02

      Disconnect the connector.

    2. Remove the 2 bolts and viscous with magnet clutch heater assembly.

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


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

  10. REMOVE GENERATOR ASSEMBLY

    A01DXLF

    1. Remove the nut and generator wire.

    2. Disconnect the generator connector.

    3. Remove the 2 bolts and generator.

  11. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01DVWSE01

      Remove the 4 bolts and V-ribbed belt tensioner.

  12. REMOVE NO. 4 INJECTION PIPE


    1. A01E10I

      Remove the bolt and disconnect 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. A01DVY2E05

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

  13. 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. A01E177

      Remove the 3 bolts and disconnect the 4 connectors.

    2. A01DXC5E01

      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.

    3. Disconnect the ventilation hose.

    4. A01DZGHE01

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

    5. A01DV31

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

  14. REMOVE NO. 1 TIMING BELT COVER


    1. Remove the bolt and water hose clamp.

    2. Remove the wire harness clamp.

    3. A01E0I5

      Remove the 6 bolts and timing belt cover.

  15. REMOVE TIMING BELT


    1. A01DWQTE02

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

    2. A01E0E0E01

      Uniformly loosen the 2 bolts and remove the timing belt tensioner.

    3. Remove the timing belt.

    4. Using a 10 mm hexagon wrench, remove the bolt, timing belt idler and washer.

      Tech Tips

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      • When turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise.

      • When installing the timing belt, return the camshaft to the timing marks and then turn the crankshaft clockwise until it aligns with the timing marks, as shown in the illustration.

  16. REMOVE CAMSHAFT TIMING PULLEY


    1. A01DV9RE01

      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 the camshaft timing pulley.

    2. Remove the camshaft timing pulley.

  17. REMOVE NO. 2 TIMING BELT COVER


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

  18. REMOVE CYLINDER BLOCK INSULATOR


    1. A01E2IC

      Remove the cylinder block insulator from the cylinder head.

  19. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01DWA8

      Remove the 2 nuts, 5 bolts, engine water pump and gasket.