GSIC - Global Service Information Center

# WATER PUMP > REMOVAL

## for Preparation Click here

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 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

5. REMOVE FAN SHROUD

1. Remove the 3 bolts and oil reservoir.

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

1. Remove the 2 bolts and radiator reservoir.

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

1. Remove the drive belt (Click here).

1. Remove the 2 bolts holding the fan shroud.

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

   NOTICE:
     Be careful not to damage the radiator core.

1. Remove the fan pulley from the water pump.

6. REMOVE COOLER COMPRESSOR ASSEMBLY

1. Remove the 4 bolts and compressor.

7. REMOVE GENERATOR ASSEMBLY

1. Remove the nut and generator wire.

1. Disconnect the generator connector.

1. Remove the 2 bolts, adjusting bar and generator.

8. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

1. Remove the 4 bolts and tensioner.

9. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

1. Disconnect the manifold absolute pressure sensor connector.

1. Disconnect the vacuum hose from the gas filter.

1. Loosen the 2 clamps of the No. 1 and No. 2 air hoses.

1. Remove the bolt and cleaner pipe together with the 2 air hoses.

10. REMOVE NO. 1 TIMING BELT COVER

1. Remove the bolt and water hose clamp.

1. Remove the wire harness clamp.

1. Remove the 6 bolts and timing belt cover.

11. REMOVE TIMING BELT

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

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

1. Remove the timing belt.

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

   HINT:
   2. When turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise.
   3. 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 INJECTION PIPE

NOTICE:

1. After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.
2. After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

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

1. Remove the bolt and No. 2 injection pipe clamp.

1. Using SST, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

   SST
     09023-12701

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

   2. Using SST, loosen the union nuts and remove the No. 4 injection pipe.

      SST
        09023-12701

14. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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

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

15. REMOVE CAMSHAFT TIMING PULLEY

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

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

1. Remove the camshaft timing pulley.

16. REMOVE NO. 2 TIMING BELT COVER

1. Remove the 4 bolts, nuts and timing belt cover.

17. REMOVE WATER PUMP ASSEMBLY

1. Remove the 2 nuts, 6 bolts, water pump and gasket.