WATER PUMP (for DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes, clean them with a brush and compressed air.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  2. REMOVE NO. 1 ENGINE UNDER COVER

  3. 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
  4. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER

    Click here

  5. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01DW4L

      Remove the bolt, nut and 2 No. 2 injection pipe clamps.

    2. A01E26N

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

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


    1. A01DYAV

      Remove the 3 bolts and No. 2 cylinder head cover.

  7. 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. A01DXC5E01

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

    2. Disconnect the ventilation hose.

    3. A01DYWG

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

    4. A01DV31

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

  8. REMOVE RADIATOR HOSE INLET

  9. REMOVE FAN SHROUD


    1. A01DZXC

      Remove the 3 bolts and oil reservoir.

    2. A01DXSK

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

    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 water pump.

  10. DISCONNECT COOLER COMPRESSOR ASSEMBLY


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

      Tech Tips

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

  11. REMOVE VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous Heater)

    Click here

  12. REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous Heater)


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

  13. REMOVE NO. 2 IDLE PULLEY ASSEMBLY


    1. Remove the bolt, pulley plate, No. 2 idle pulley and spacer.

  14. REMOVE GENERATOR ASSEMBLY

    A01DXLF

    1. Remove the nut and generator wire.

    2. Disconnect the generator connector.

    3. Remove the 2 bolts and generator.

  15. REMOVE GENERATOR BRACKET


    1. Remove the bolt and generator bracket.

  16. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01DVWSE01

      Remove the 4 bolts and V-ribbed belt tensioner.

  17. REMOVE NO. 1 TIMING BELT COVER


    1. A01E1VTE01

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

  18. REMOVE TIMING BELT


    1. A01DWQTE05
      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. A01E0E0E01

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

    3. Remove the timing belt.

      Tech Tips

      A01DYCXE02

      • 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.

  19. 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.

  20. 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.

  21. REMOVE NO. 2 TIMING BELT COVER


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

  22. REMOVE CYLINDER BLOCK INSULATOR


    1. A01E2IC

      Remove the cylinder block insulator from the cylinder head.

  23. REMOVE WATER PUMP ASSEMBLY


    1. A01E0AX

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

      Text in Illustration
      A01E2TX Bolt
      A01DZ8Z Nut