Coolant Pump - 3.5L GTDI: Installation
- 2.
Install the coolant pump and the 8 bolts. Tighten the 8 bolts in the sequence shown in illustration in 2 stages:- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees
- 3.NOTE: 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).
- 5.
Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.- Align the colored links with the timing marks.
- 6.
Position the RH secondary timing assembly onto the camshafts and install the new VCT bolt and the 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.
- 9.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.
- 12.
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.
- 1.
- 13.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 Lock Pin.
- 14.
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 colored links (3).
- 15.NOTE: RH shown in illustration, 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.
Visual check the VCT housing-to-cylinder head O-ring seals and VCT housing seals for damage and replace as necessary.
- 16.NOTE: Make sure the dowels on the VCT housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage.
Install the LH VCT housing and the 3 bolts.
- Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
- 17.NOTE: Make sure the dowels on the VCT housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this instruction will result in severe engine damage.
Install the RH VCT housing and the 3 bolts.
- Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
- 19.
Install the engine front cover. Refer to ENGINE - 3.5L GTDI .
- 20.
Fill and bleed the cooling system. Refer to Cooling System Draining, Filling and Bleeding .