Water Pump: Service and Repair

Coolant Pump - 3.5L, 3.7L

























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. For additional information, refer to Cooling System Draining, Filling and Bleeding Service and Repair.

2. Remove the engine front cover.

3. Rotate the crankshaft clockwise and align the timing marks on the intake Variable Camshaft Timing (VCT) assemblies as shown.





4. Remove the 3 bolts and the LH valve train oil tube.





5. NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.
Install the Camshaft Holding Tool onto the flats of the LH camshafts.






6. Remove the 3 bolts and the RH valve train oil tube.





7. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC (Top Dead Center) position.
Install the Camshaft Holding Tool onto the flats of the RH camshafts.






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 (Variable Camshaft Timing) assembly as shown.





9. Mark the timing chain link that aligns with the timing mark on the RH intake VCT (Variable Camshaft Timing) 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.






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





12. Remove the primary timing chain tensioner arm.





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





14. NOTE: Removal of the VCT (Variable Camshaft Timing) 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 (Variable Camshaft Timing) oil control solenoid.

NOTE: Keep the VCT (Variable Camshaft Timing) oil control solenoid clean of dirt and debris.
Remove the bolt and the LH intake VCT (Variable Camshaft Timing) oil control solenoid.






15. NOTE: Removal of the VCT (Variable Camshaft Timing) 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 (Variable Camshaft Timing) oil control solenoid.

NOTE: Keep the VCT (Variable Camshaft Timing) oil control solenoid clean of dirt and debris.
Remove the bolt and the RH intake VCT (Variable Camshaft Timing) oil control solenoid.






16. Remove the primary timing chain.





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

Remove the bolt and the upper LH primary timing chain guide.






18. NOTE: The 2 VCT (Variable Camshaft Timing) oil control solenoids are removed for clarity.

NOTE: The Secondary Chain Hold Down is inserted through a hole in the top of the mega cap.
Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down 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.






19. Remove and discard the 2 RH VCT (Variable Camshaft Timing) assembly bolts.





20. Remove the 2 RH VCT (Variable Camshaft Timing) assemblies and secondary timing chain.





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

Remove the bolt and the RH primary timing chain guide.






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. Remove the 8 bolts, the coolant pump and the 2 gaskets.
- Discard the gaskets.


Installation

1. Install 2 new gaskets, the coolant pump and the 8 bolts.
- 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. Install the RH primary timing chain guide and the bolt.
- Tighten to 10 Nm (89 lb-in).






6. Assemble the RH VCT (Variable Camshaft Timing) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.
- 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 (Variable Camshaft Timing) assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT (Variable Camshaft Timing) assemblies with the dowel pins in the camshafts.






8. Install the 2 new RH VCT (Variable Camshaft Timing) 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 (Variable Camshaft Timing) oil control solenoids are removed for clarity.
Compress the RH secondary timing chain tensioner and remove the Secondary Chain Hold Down.

- Make sure the secondary timing chain is centered on the timing chain tensioner guides.






10. Install the upper LH primary timing chain guide and the bolt.
- 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 (Variable Camshaft Timing) assemblies and the crankshaft sprocket.






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






13. Install the primary timing chain tensioner arm.





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 suitable lockpin.






15. NOTE: It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to install the tensioner.
Install the primary tensioner and the 2 bolts.

- Tighten to 10 Nm (89 lb-in).

- Remove the lockpin.






16. As a post-check, verify correct alignment of all timing marks.
- There is 48 links in between the RH intake VCT (Variable Camshaft Timing) assembly colored link (1) and the LH intake VCT (Variable Camshaft Timing) assembly colored link (2).

- There is 35 links in between LH intake VCT (Variable Camshaft Timing) assembly colored link (2) and the 2 crankshaft sprocket links (3).






17. NOTICE: Do not use excessive force when installing the Variable Camshaft Timing (VCT) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT (Variable Camshaft Timing) oil control solenoid, inspect the bore and VCT (Variable Camshaft Timing) 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 (Variable Camshaft Timing) oil control solenoid.

NOTE: Keep the VCT (Variable Camshaft Timing) oil control solenoid clean of dirt and debris.

Install the LH intake VCT (Variable Camshaft Timing) oil control solenoid and the bolt.
- Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.






18. NOTICE: Do not use excessive force when installing the Variable Camshaft Timing (VCT) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT (Variable Camshaft Timing) oil control solenoid, inspect the bore and VCT (Variable Camshaft Timing) 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 (Variable Camshaft Timing) oil control solenoid.

NOTE: Keep the VCT (Variable Camshaft Timing) oil control solenoid clean of dirt and debris.

Install the RH intake VCT (Variable Camshaft Timing) oil control solenoid and the bolt.
- Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.






19. Remove the RH Camshaft Holding Tool.





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 Camshaft Holding Tool.





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.

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.


26. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding Service and Repair.