Coolant Pump — 3.5L GTDI

Special Tool(s)

Camshaft Holding Tool 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 may cause engine failure.

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02 .

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

3. Remove the engine front cover. Refer to Section 303-01B .

4. Remove and discard the engine oil filter.

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

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

   Install the Camshaft Holding Tool onto the flats of the LH camshafts.

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

   Install the Camshaft Holding Tool onto the flats of the RH camshafts.

8. Remove the 3 bolts and the RH VCT housing.

9. Remove the 3 bolts and the LH VCT housing.

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

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

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

12. Mark the timing chain link that aligns with the timing mark on the crankshaft sprocket as shown.

13. Remove the 2 bolts and the primary timing chain tensioner.

14. Remove the primary timing chain tensioner arm.

15. Remove the 2 bolts and the lower LH primary timing chain guide.

16. Remove the primary timing chain.

17. Remove the 2 bolts and the upper LH primary timing chain guide.

18. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.

19. NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.

    Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt.
    • Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.

20. Remove the bolt and the RH primary timing chain guide.

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

22. Remove the 8 bolts and the coolant pump.

Installation

1. NOTE: Clean and inspect all sealing surfaces.

   Install a new gasket, the coolant pump and the 8 bolts. Tighten in the sequence shown in 2 stages:
   • Stage 1: Tighten to 10 Nm (89 lb-in).
   • Stage 2: Tighten an additional 45 degrees.

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

3. 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 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).

4. Install the RH primary timing chain guide and the bolt.
   • Tighten to 10 Nm (89 lb-in).

5. Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain.
   • Align the colored links with the timing marks.

6. Position the LH secondary timing assembly onto the camshafts.

7. Install the new VCT bolt and new exhaust camshaft bolt and the original washer. Tighten in 4 stages.
   • Stage 1: Tighten to 40 Nm (30 lb-ft).
   • Stage 2: Loosen one full turn.
   • Stage 3: Tighten to 10 Nm (89 lb-in).
   • Stage 4: Tighten 90 degrees.

8. Remove the lockpin from the LH secondary timing chain tensioner.

9. Install the upper LH primary timing chain guide and the bolt.
   • Tighten to 10 Nm (89 lb-in).

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

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

11. Install the lower LH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).

12. Install the primary timing chain tensioner arm.

13. Reset the primary timing chain tensioner.
    1. Release the ratchet detent.
    2. Using a soft-jawed vise, compress the ratchet plunger.
    3. Align the hole in the ratchet plunger with the hole in the tensioner housing and install a suitable lockpin.

14. NOTE: It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner.

    Install the primary tensioner and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    • Remove the lockpin.

15. 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 sprockets colored links (3).

16. Inspect the VCT housing seals for damage and replace if necessary.

17. NOTE: RH shown, LH similar.

    NOTE: During removal, the O-ring seal may remain on the cylinder head. If so, remove the O-ring seal from the cylinder head, inspect the seal (replace as necessary) and install the O-ring seal on the VCT housing.

    Inspect the VCT housing-to-cylinder head O-ring seals for damage and replace as necessary.

18. NOTE: Make sure the dowels on the VCT housing are fully engaged in the cylinder head prior to tightening the bolts.

    Install the LH VCT housing and the 3 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).

19. NOTE: Make sure the dowels on the VCT housing are fully engaged in the cylinder head prior to tightening the bolts.

    Install the RH VCT housing and the 3 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).

20. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.

    Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.

21. Install the engine front cover. Refer to Section 303-01B .

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