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
  • First time importing a vehicle and Taylor did a great job guiding me the entire way! 5 star service! Excited about my new mini truck!

    Ryan White Avatar
    Ryan White
    1/18/2022

    Good experience throughout the entire process. They had the patience to help me find what I was looking for, when it arrived it was in great condition as I expected... read more

    Michael Jones Avatar
    Michael Jones
    1/13/2022

    First time customer review:
    All around a great company to work with. Mathew was very responsive and helped me throughout the entire process. With this being the first time importing a...
    read more

    Adam Fifield Avatar
    Adam Fifield
    1/10/2022
  • My sales rep at JCD, Taylor, was amazing. He was quick to get me auction info, provided me good insights on possible price points, and was ready to answer any... read more

    Derek Rucker Avatar
    Derek Rucker
    12/15/2021

    Mathew was extremely patient with me from start to finish, during a time when COVID backlogs and the Suez canal blockage happened - can only imagine this being mega stressful... read more

    Adam Delaney Avatar
    Adam Delaney
    11/24/2021

    10 stars for service! This was my first time importing, we used JCD on a recommendation from a friend and I was really blown away by the service which Andrew... read more

    Jeff Cheok Avatar
    Jeff Cheok
    10/21/2021
  • In a time were lots of exporters are trying to make a quick dollar and sell you a rusty car, Japan Car Direct looks out for you and makes sure... read more

    Sebastian Kurpiel Avatar
    Sebastian Kurpiel
    10/01/2021

    Hey Matt, thanks for all the help in locating the perfect vehicle for our acreage. We cannot say enough good things about the service you provided. Your... read more

    Angela Butler Avatar
    Angela Butler
    9/06/2021

    After deciding to import a vehicle myself from Japan to the US, Japan car direct was one of the first names to come up. Of course this being the first... read more

    LelandLs6 T Avatar
    LelandLs6 T
    7/28/2021
  • I had a great experience with Japan Car Direct. Matt helped answer all my questions and guide me thru the process successfully. Buying a car sight unseen can be stressful... read more

    Jake Metz Avatar
    Jake Metz
    7/19/2021

    Great to do business with. Mathew was very helpful and guided me through the process to import a Nissan Elgrande. I can thoroughly recommend them for anyone else... read more

    Jonathan Pyne Avatar
    Jonathan Pyne
    7/16/2021

    I just bought a suzuki carry from Japan. Taylor was super helpful and supportive during the process, all the way up to picking up my truck at the port! Definitely... read more

    Landon Sutherland Avatar
    Landon Sutherland
    7/01/2021
  • This was my first time ever purchasing vehicles from Japan. Mathew was recommend to me by a friend and I would not hesitate to recommend him to anyone else. Besides... read more

    Jonathan Wells Avatar
    Jonathan Wells
    6/21/2021

    Mathew was great to work with and everything went well through the auction and export process. He was very patient with all my questions since it was my first... read more

    Jack Wagner Avatar
    Jack Wagner
    5/29/2021

    JCD was great to work with. Mathew was patient with me as I searched for my dream vehicle. He explained the process and helped me understand how to eliminate as... read more

    Greg Thompson Avatar
    Greg Thompson
    5/20/2021
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