Coolant Pump — 3.5L Ti-VCT

Special Tool(s)

	Hold Down, Secondary Chain 303-1530
	Tool, Camshaft Holding 303-1248

Removal

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

1. Drain the cooling system. Refer to Cooling System Draining, Filling and Bleeding .

2. Remove the engine front cover. Refer to Section 303-01A .

3. Rotate the crankshaft clockwise and align the timing marks on the intake VCT assemblies as shown.

5. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

   • Special tool: Tool, Camshaft Holding

7. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

   • Special tool: Tool, Camshaft Holding

NOTE: The following 3 steps are for primary timing chains that the colored links are not visible.

8. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown.

9. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown.

10. NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.

    Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown.

14. NOTE: Removal of the VCT oil control solenoid will aid in the removal of the primary timing chain.

    NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoid.

    NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

15. NOTE: Removal of the VCT oil control solenoid will aid in the removal of the primary timing chain.

    NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoid.

    NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

17. NOTICE: Do not use power tools to remove the bolt or damage to the LH primary timing chain guide may occur.

18. NOTE: The 2 VCT oil control solenoids are removed for clarity.

    NOTE: The Hold Down, Secondary Chain is inserted through a hole in the top of the mega cap.

    Compress the RH secondary timing chain tensioner and install the Hold Down, Secondary Chain in the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to retain the tensioner in the collapsed position.
    • Special tool: Hold Down, Secondary Chain

21. NOTICE: Do not use power tools to remove the bolt or damage to the RH primary timing chain guide may occur.

22. Place clean lint-free shop towels in the oil pan opening to prevent coolant from entering the oil pan during coolant pump removal.

23. Discard the specified component. Follow local disposal regulations.

Installation

1. Install 2 new gaskets.
   • Tighten the bolts finger tight.

2. Tighten the coolant pump bolts in the sequence shown in 2 stages.
   • Stage 1: Tighten to 10 Nm (89 lb-in).
   • Stage 2: Tighten an additional 45 degrees.

3. Remove all of the shop towels from the oil pan opening.

4. NOTICE: Any coolant that has accumulated in the oil pan must be drained from the pan and any residual coolant cleaned from the front of the engine and the oil pan. Failure to remove all traces of the coolant can result in oil contamination and severe engine damage.

   Remove the oil pan drain plug and allow any accumulated coolant to drain.
   • Remove any residual coolant from the front of the engine and the oil pan using regulated compressed air and clean lint-free shop towels.
   • Install the oil pan drain plug and tighten to 27 Nm (20 lb-ft).

5. • Tighten to 10 Nm (89 lb-in).

6. • Align the colored links with the timing marks.

7. NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly.

   Position the 2 RH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.

8. Install the 2 new RH VCT bolts and tighten in 4 stages.
   • Stage 1: Tighten to 40 Nm (30 lb-ft).
   • Stage 2: Loosen one full turn.
   • Stage 3: Tighten to 25 Nm (18 lb-ft).
   • Stage 4: Tighten an additional 180 degrees.

9. NOTE: The 2 VCT oil control solenoids are removed for clarity.

   Compress the RH secondary timing chain tensioner and remove the Hold Down, Secondary Chain.
   • Make sure the secondary timing chain is centered on the timing chain tensioner guides.

10. • Tighten to 10 Nm (89 lb-in).

11. NOTE: It may be necessary to rotate the camshafts slightly, to align the timing marks.

    Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.

12. • Tighten to 10 Nm (89 lb-in).

14. Reset the primary timing chain tensioner.
    • Release the ratchet detent.
    • Using a soft-jawed vise, compress the ratchet plunger.
    • Align the hole in the ratchet plunger with the hole in the tensioner housing.
    • Install a lockpin.

15. NOTE: It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to install the tensioner.

    • Tighten to 10 Nm (89 lb-in).
    • Remove the lockpin.

16. As a post-check, verify correct alignment of all timing marks.
    • There are 48 links between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2).
    • There are 35 links between the LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket links (3).

17. NOTICE: Do not use excessive force when installing the VCT oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.

    NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.

    NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

    • Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.

18. NOTICE: Do not use excessive force when installing the VCT oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.

    NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.

    NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

    • Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.

19. Remove the RH Tool, Camshaft Holding.

20. Install the RH valve train oil tube and the 3 bolts and tighten in 2 stages.
    • Stage 1: Tighten to 8 Nm (71 lb-in).
    • Stage 2: Tighten an additional 45 degrees.

21. Remove the LH Tool, Camshaft Holding.

22. Install the LH valve train oil tube and the 3 bolts and tighten in 2 stages.
    • Stage 1: Tighten to 8 Nm (71 lb-in).
    • Stage 2: Tighten an additional 45 degrees.

23. Install the engine front cover. Refer to Section 303-01A .

24. Remove and discard the engine oil filter.

25. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installation.

    Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
    • Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)

26. Fill and bleed the cooling system. Refer to Cooling System Draining, Filling and Bleeding .