WATER PUMP (w/o 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 NO. 1 ENGINE UNDER COVER


    1. Remove the 4 bolts and cover.

  3. DRAIN ENGINE COOLANT


    1. Drain the engine coolant Click here.

  4. DISCONNECT RADIATOR HOSE INLET


    1. Disconnect the hose from the radiator tank upper.

  5. REMOVE FAN SHROUD

    A01E2XJE01

    1. Remove the 3 bolts and oil reservoir.

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

    3. Remove the 2 bolts and radiator reservoir.

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

    5. Remove the drive belt Click here.

    6. Remove the 2 bolts holding the fan shroud.

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

      Note

      Be careful not to damage the radiator core.

    8. Remove the fan pulley from the water pump.

  6. REMOVE COOLER COMPRESSOR ASSEMBLY


    1. Remove the 4 bolts and compressor.

  7. REMOVE GENERATOR ASSEMBLY

    A01DXLF

    1. Remove the nut and generator wire.

    2. Disconnect the generator connector.

    3. Remove the 2 bolts and generator.

  8. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. Remove the 4 bolts and tensioner.

  9. REMOVE CHARGE AIR COOLER ASSEMBLY


    1. Remove the CAC Click here.

  10. REMOVE NO. 1 TIMING BELT COVER

    A01E1VTE01

    1. Remove the bolt and water hose clamp.

    2. Remove the wire harness clamp.

    3. Remove the 6 bolts and timing belt cover.

  11. REMOVE TIMING BELT

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    1. 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

      A01DYCXE02

      • 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.

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

  13. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Note


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

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


    1. A01DXPXE01

      Remove the bolt and No. 2 injection pipe clamp.

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

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

  14. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01E0ZRE01

      Remove the 2 bolts and disconnect the 2 injection pipe clamps.

      Note

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

    2. A01E2XGE01

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

  15. 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 holder seal by prying the portion between the holder seal and the cutout part of the cylinder head.

    3. Disconnect the ventilation hose.

    4. A01DZGHE01

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

    5. A01DV31

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

  16. CLEAN CAMSHAFT TIMING PULLEY


    1. A01DV9RE01

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

      Note

      Make sure to remove the bolt of the camshaft timing pulley with the timing belt not installed.

    2. Remove the camshaft timing pulley.

  17. REMOVE NO. 2 TIMING BELT COVER


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

  18. REMOVE WATER PUMP ASSEMBLY


    1. A01DWA8

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