KS4 Subaru Sambar: Timing belt water pump replacement

Vehicle Search Engine: Over 150,000 vehicles at auction weekly, plus thousands more on dealer lots.
Let’s find the ideal car for you today!!


KS4 Subaru Sambar timing belt water pump replacement

How to replace the Timing Belt/Water Pump on our KS4 Supercharged Sambar:

Open the rear engine access compartment cover underneath the rear gate.  It helps to press the top of the cover inwards towards the front of the truck while you turn the key, especially if it hasn’t been opened in a while [Image 1].

ks4-diy-01

[Image 1]

Loosen the lug nuts on the right rear wheel and jack up the vehicle and place the rear of the truck on jackstands securely.  Remove the right rear wheel [Image 2].

ks4-diy-02

[Image 2]

Remove the upper shock bolt in order to access the plastic cover.  We sprayed the bolts with penetrating oil in order to aid bolt removal.  The bottom of the cover is attached to the cross brace and it is easier to remove the cross brace as one unit with the cover by removing the two bolts that hold the cross brace to the frame [Image 3].

ks4-diy-03

[Image 3]

Once the cover is removed, access the crank pulley and oil filter is granted [Image 4].

ks4-diy-04

[Image 4]

At this point, we sprayed al the bolts we will be accessing with penetrating oil.  Take care not to spray on any belts.

Loosen the two belts (if you have a Supercharged AC version) by accessing the bolt from the bed and from the side [Images 5-1 and 5-2].

ks4-diy-05

[Image 5-1]

ks4-diy-06

[Image 5-2]

Remove the belts once the tension is reduced.

Use an impact driver to remove the crank pulley bolt.  If you do not have an impact driver, the left half of the timing belt cover can be removed to access the camshaft pully which can be secured in order to remove the crankshaft pulley bolt [Image 6].

ks4-diy-07

[Image 6]

Use a pulley remover to remove the crankshaft pulley from the crankshaft [Image 7].

ks4-diy-08

[Image 7]

Remove all of the bolts holding the two parts of the plastic timing belt cover.  It helps to remove the bolt holding the ground wire to the valve cover and to slide out the oil dipstick tube.  Only one bolt holds the dipstick tube to the timing belt cover.

Both of the timing belt pulleys have a dimple on one of the teeth.  Make note of the positioning of the marks before removing the tensioner (3rd picture) and remove the timing belt [Images 8-1, 8-2 and 8-3].

ks4-diy-09

[Image 8-1]

ks4-diy-10

[Image 8-2]

ks4-diy-11

[Image 8-3]

Although we’ll get to the water pump later, spray the water pump bolts with penetrating oil now.

Once the timing belt is removed, slide off the crankshaft timing belt pulley to access the crankshaft front seal [Image 9].

ks4-diy-12

[Image 9]

The seal can be pried out.  Take care not to scratch the crankshaft or the crankcase when prying out the seal.

Old Seal VS new [Image 10] .

ks4-diy-13

[Image 10]

Put a little grease on the new seal and press it into place.  You can use the old seal, place it backwards over the new seal, and use it to help push the new seal into place.

Hold the cam timing belt pulley in place and remove the three bolts holding the pulley in place.  Remove the pulley and the plastic timing chain rear cover to access the camshaft oil seal [Image 11].

ks4-diy-14

[Image 11]

Pry out the camshaft oil seal in the same manner as the crankshaft oil seal earlier and replace.

Old Seal VS new [Image 12].

ks4-diy-15

[Image 12]

Place a pan underneath the water pump and remove the 6 bolts securing the water pump to the engine.  The four rubber pieces can that seal the water pump on the corners can be carefully pried out now.  Once the bolts are removed, the water pump can be pried off.  There is a dowel holding the water pump in place so it must be removed somewhat evenly [Image 13].

ks4-diy-16

[Image 13]

Remove the old gasket and clean up the mating surface.

The instructions for the new water pump said “do not turn the water pump before installing,” and “install the water pump gasket dry”.  Taking care to follow those instructions, place the gasket in the groove and install the water pump.  Water pump bolt torque specs are 1.7 kgf/m [Image 14].

ks4-diy-17

[Image 14]

Bolt on the plastic timing belt backing cover and replace the cam pully [Image 15].

ks4-diy-18

[Image 15]

Replace the rubber seals on the corners of the water pump [Image 16].

ks4-diy-19

[Image 16]

The new timing belt has two white marks that line up with the dimples on the pulleys.  Slide the crankshaft pulley back on to the crankshaft and slip the belt over the pulleys making sure to line up the white marks with the dimples [Image 17].

ks4-diy-20

[Image 17]

Take the spring off of the old tensioner and place it on the new one and install the tensioner. Tensioner bolt torque is 25±3 N・m  [Image 18].

ks4-diy-21

[Image 18]

Do one last check to make sure the white lines on the timing belt is still lined up with the dimples on the pulleys and install the right-side timing belt cover.  Don’t forget to reinstall the oil dipstick tube if it was removed. Before you install the left cover, secure the camshaft pulley and install the crankshaft pulley and tighten the crankshaft pulley bolt to 108±10 Nm.  Install the left-side timing belt cover [Image 19].

ks4-diy-22

[Image 19]

Reinstall the tensioners and alternator/supercharger/ac belts.  Add coolant to make up for the amount drained when the water pump was removed [Image 20] .

ks4-diy-23

[Image 20]

Contact Japan Car Direct today. We can help you find, purchase and import the secondhand car you seek at a reasonable price from auctions and dealers all over Japan.

google-review
  • It was my first time buying a car online, let alone overseas. These guys are legit!!!
    Yoshi has been very patient, transparent and prompt with all queries. The car was exactly...
    read more

    Bobby Capa Avatar
    Bobby Capa
    11/22/2022

    FIRST TIME BUYER
    So…. I have just ordered my second car from Yoshiro Nakajima at Japan Car Direct. Keep in mind my first car has only just gotten to the port,...
    read more

    Alpesh Patel Avatar
    Alpesh Patel
    9/11/2022

    Great service. This was my first time importing a car from Japan. Everything was well explained and the whole process went very smooth. Would highly recommend!! Thank you Yoshi!

    John Power Avatar
    John Power
    9/08/2022
  • Importing through Japan Car Direct has been a great experience through and through. Their assistance in the auction and bidding process and arranging shipping is top notch. More importantly their... read more

    Peter Hagemeyer Avatar
    Peter Hagemeyer
    9/07/2022

    Awesome experience working with Taylor, he was extremely helpful and patience. It was my first time exporting a vehicle and he walked me through step by step and didn't... read more

    Eric Southerland Avatar
    Eric Southerland
    9/06/2022

    Japan Car Direct made buying a car from Japan dangerously easy. 🙂 Yoshiro was a great help. He was responsive and supportive through the whole process. They have... read more

    Tim Meunier Avatar
    Tim Meunier
    9/04/2022
  • I had an excellent experience working with Matthew at Japan Car Direct. I was a first time auction buyer and importer to the United States. Mathew walked me through... read more

    Alex Spiegel Avatar
    Alex Spiegel
    8/11/2022

    A great experience for my first time importing a car from Japan. Mike’s customer service was second to none and all the paperwork was in order.

    Bobby Crumpley Avatar
    Bobby Crumpley
    8/03/2022

    Matthew at JCD is the man. I’ve now imported three of my own cars through him. JCD was able to accommodate my unique needs, everything from short turn around inspections,... read more

    Chan Shin Avatar
    Chan Shin
    7/29/2022
  • I highly recommend Japan Car Direct. They help you find exactly what you are looking for and are with you throughout the entire process. Import was seamless. Mike was great... read more

    Sir Selrahc Avatar
    Sir Selrahc
    7/14/2022

    Before this I have never imported any vehicles to NZ let alone one from Japan! I decided to give these guys a shot and bought a JDM Tesla into the... read more

    Edward Yuan Avatar
    Edward Yuan
    7/11/2022

    Great experience. Extremely easy process and Kept me well informed. Highly recommend them if looking to purchase a vehicle from Japan.

    Antonio Sevilla Avatar
    Antonio Sevilla
    7/08/2022
  • It's hard to say anything that hasn't been said from other reviewers! This was my first experience importing a vehicle. Mike Nguyen was super patient with me and my indecisiveness.... read more

    Law_of_the Za Avatar
    Law_of_the Za
    6/30/2022

    I used Japan Car Direct's services to import a Nissan Silvia from Japan to Australia. Mike was very helpful from start to finish and definitely made the process stress free.

    The...
    read more

    matthew martin Avatar
    matthew martin
    6/24/2022

    Just picked up my car that I bought through JCD. I was a complete newbie about buying a car overseas and Mathew was kind enough to basically hold my... read more

    TK Mad Avatar
    TK Mad
    6/18/2022
Japan Car Direct provides friendly, honest, efficient service. Get the vehicles you want today at a price you can afford!!

We accept refundable deposits by PayPal to ([email protected]). Log into your account, and lets start working together today!
paypal-logo3

Back to top
JCD Menu logo