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
  • 5 star review  Great experience working with Japan Car Direct. Very helpful, great communication and very patient with a first time mini truck buyer and importer.

    thumb Sven MacAller
    4/06/2021

    5 star review  I can't recommend JCD enough. Mathew was a fantastic person to work with. As a newbie to the Japanese auctions, I was quite naïve and had far too many questions. Mathew was kind, knowledgeable, and patient through the entire process. My Minicab arrived last week and I am quite pleased. I would not hesitate to work with Japan Car Direct again in the future. Thank you Mathew!! Jay A.

    thumb Acute Autoworks
    2/26/2021

    5 star review  I purchased a suzuki carry from here.. They made the whole process so easy..fantastic communication,and I got what I wanted.. highly recommend using this company for your next purchase. 5 stars

    thumb Alec KELSEY
    2/21/2021
  • 5 star review  IF YOU ARE OVERLY CAUTIOUS READ THIS I am over the top and I am aware of it. Matthew probably should get an award for dealing with me. I dig into everything and am used to fighting for fairness at auto auctions here in the USA - we own a small dealership. Early into my fist purchase (of many) Matthew earned my trust. He’s a rare breed: a true professional and exceptional at what he does. The world NEEDS more like him in every industry. Matthew is one of our most valued partners now, as we strive to bring JDM to Rochester and the Great Lakes. I’m a tough case, I openly admit, but he worked through my caution and I’m now very happy to purchase through him. Call me if you want, I’ll recommend Matthew to anyone. Drew

    thumb Drew Carapella
    2/19/2021

    5 star review  IF YOU ARE OVERLY CAUTIOUS READ THIS I am over the top and I am aware of it. Matthew probably should get an award for dealing with me. I dig into everything and am used to fighting not to get taken at local auctions (I own a dealership and believe strongly in integrity). Early into my fist purchase (of many) Matthew earned my trust. He’s a rare breed: a true professional and exceptional at what he does. The world NEEDS more like him in every industry. Matthew is one of our most valued partners now, as we strive to bring JDM to Rochester and the Great Lakes. I’m a tough case, I openly admit. Find me and call me if you want, I’ll recommend Matthew to anyone. Drew

    thumb Drew Carapella
    2/19/2021

    5 star review  I always wanted a Land Cruiser ! Mathew helped me find 2 beautiful trucks from the Japanese auction. Had them delivered to Freeport, TX last week. He was amazing to work with. Fast response time on bids, super easy to work with, he has a lot of experience and answered all questions promptly. Will be working with JCD more in the future to purchase more vehicles !

    thumb Vince Jabbal
    2/10/2021
  • 5 star review  Very pleased with my experience with JCD. Mat helped me with my purchase of a Honda Beat and its shipping to the port of Baltimore. Everything was seamless and I would (and already have) recommended this company to several friends.

    thumb Justin Marvel
    2/01/2021

    5 star review  Thanks to JapanCarDirect for the opportunity, Yoshi took well care of my requests with a incomparable patience and fast follow up. Will definitely pass the word around !!! 👌🇨🇦🇯🇵

    thumb Ray Mechanic
    1/25/2021

    5 star review  Fantastic service, helped me through the process of importing my JZX100 to the UK, Everything was clear and fees were low, worth every penny though, fantastic and couldn't have asked for more!

    thumb Jack Ellis
    1/19/2021
  • 5 star review  I just picked up my dream campervan from port and have to say that Japan car direct was with me the entire way. I felt so supported all my questions were answered and I could not imagine doing something like this without them. I highly recommend the whole team, trust them and would encourage anyone to use there services.

    thumb scott snow
    12/23/2020

    5 star review  Mathew and all stuff JCD are best. I ordered 4 cars to UA. Support was 24H. The team did its best to solve my problems. They are really good. Now I can recommend them. Unique condition of the car. P.S. sorry but the photo was taken immediately upon arrival. Thank you again!

    thumb Oleg Dziuba
    11/23/2020

    5 star review  I just wanna thank Matthew and the whole team at Japan Car Direct, they always went above and beyond in making sure their clients are always happy and informed about the vehicles they are purchasing. I am still in the buying process but so far 5/5 definitely. I’ll keep everyone posted when I do find a car!

    thumb Mahad Awan
    11/10/2020
  • 5 star review  Do yourself a favor, call Mathew at Japan Car Direct. Let him take the worry about doing business over seas off your plate. Not knowing anything about importing vehicles from Japan, I spent countless hours studying and trying to figure it all out. The headaches were too much! After Mathew walked me through the process it was a piece of cake. We've already bought a couple and are now buying more with complete confidence. Thanks guys, much much appreciated.

    thumb Richard Harris
    10/23/2020

    5 star review  Can not recommend these guys enough. I dealt with Matt, who was extremely helpful and patient with all of my stupid questions. The way they have the whole process is so convenient, especially with the live video translations of the auction sheets. I will absolutely be returning to them in the future.

    thumb Seaver Brown
    10/10/2020

    5 star review  Trustworthy group here! They made it easy from point a to b. So glad this was the first group I tried as I have heard horror stories about the import process. Highly recommended.

    thumb Cory Cheyne
    9/22/2020
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