Replace the internal timing chain-driven water pump on the 3.5L EcoBoost engine, requiring timing cover removal and coolant system drain.

Warnings

Tools required

Parts

• Water pump assembly with gasket × 1 — Ford BT4Z-8501-A or equivalent
• Timing cover gasket × 1 — Use OEM specification
• Thermostat housing O-ring/gasket × 1 — Use OEM specification
• Coolant hose clamps × 4 — OEM spring clamps or equivalent
• Accessory drive belt × 1 — Use OEM specification

Fluids

• Motorcraft Orange Coolant — 13 qt

Preparation

1. Ensure engine is completely cool (minimum 2 hours after last operation)
2. Disconnect negative battery cable and secure away from terminal
3. Raise vehicle on level surface and support securely on jack stands at frame rails
4. Remove engine cover by pulling upward on front edge to release clips
5. Place drain pan under radiator and open radiator drain valve at bottom corner
6. Remove radiator cap and allow coolant to drain completely from system
7. Drain coolant from engine block by removing drain plug on driver side of block if accessible
8. Check engine oil level and condition on dipstick - note any coolant contamination (milky appearance or overfill)

Procedure

1. 1

   Remove accessory drive belt and components
   Rotate accessory drive belt tensioner clockwise using 3/8" ratchet in square hole to release tension. Remove belt from all pulleys. Remove the power steering pump mounting bolts and secure pump aside without disconnecting lines. Remove alternator mounting bolts and position aside with wiring connected. Remove A/C compressor mounting bolts and secure compressor without disconnecting refrigerant lines.
2. 2

   Remove upper timing cover fasteners
   Disconnect coolant hoses from thermostat housing by releasing clamps. Remove thermostat housing bolts and set housing aside. Remove all upper timing cover bolts starting from outside working inward. There are approximately 15 bolts of varying lengths - note their positions for reassembly. Remove ignition coils from cylinder heads if they interfere with cover removal.
   Torque spec

   Thermostat Housing Bolts15 Nm (11 lb-ft)

   Hose Clamps3 Nm (2 lb-ft)
3. 3

   Access lower timing cover
   From underneath vehicle, remove lower splash shield and any cross-braces blocking access to front of engine. Remove crankshaft pulley center bolt (requires significant torque to loosen - impact wrench recommended). Use harmonic balancer puller to remove crankshaft pulley/damper. Remove remaining lower timing cover bolts from below.
4. 4

   Remove timing cover
   Carefully pry timing cover away from engine block using plastic pry tools at designated pry points (small notches). Work around perimeter evenly to break gasket seal. Do not pry against gasket surfaces. Once loose, pull cover straight forward to clear dowel pins. Timing chain and components are now exposed.
   ⚠Do not rotate crankshaft or camshafts once timing cover is removed. Rotation without alignment tools can cause piston-to-valve contact.
5. 5

   Verify and mark timing alignment
   Verify that timing marks on camshaft sprockets align with cylinder head marks and crankshaft keyway is at 12 o'clock position (TDC cylinder 1). Use paint pen or marker to mark chain position relative to sprockets for verification during reassembly. Install camshaft alignment tools into rear of camshafts through access holes in cylinder heads to lock position. Install crankshaft TDC holding tool if available.
   ⚠️Timing alignment is critical. If marks do not align correctly at TDC, do not proceed. Engine may have jumped timing and requires professional diagnosis.
6. 6

   Remove water pump mounting bolts
   Locate the internal water pump mounted on front of engine block behind timing chain. Remove all water pump mounting bolts (typically 4 bolts). Note that coolant may drain from pump cavity when removed. Pull water pump straight out from engine block to remove from dowel pins.
   ℹ️Expect residual coolant to drain from pump cavity and block passages. Keep drain pan positioned below work area.
   Torque spec

   Water Pump Bolts25 Nm (18 lb-ft)
7. 7

   Clean mounting surfaces
   Thoroughly clean water pump mounting surface on engine block using gasket scraper and wire brush. Remove all old gasket material and corrosion without gouging aluminum surface. Clean timing cover gasket surfaces on both block and cover. Inspect timing cover for cracks or warping. Wipe all surfaces with clean lint-free cloth and brake cleaner.
8. 8

   Install new water pump
   Install new gasket or O-ring on new water pump according to manufacturer instructions (may require gasket sealer or dry installation depending on design). Align water pump with dowel pins on engine block and press firmly into position. Install water pump bolts and hand-tighten in star pattern. Torque all water pump bolts to specification in three progressive steps (5 Nm, 8 Nm, then final 10 Nm) in star pattern to ensure even gasket compression.
   Torque spec

   Water Pump Bolts25 Nm (18 lb-ft)
9. 9

   Verify timing alignment before cover installation
   Double-check that camshaft alignment tools are still properly seated and timing marks remain aligned. Verify timing chain has proper tension and no slack. If chain shows excessive wear or stretch, replacement is recommended while system is disassembled. Confirm crankshaft has not rotated from TDC position.
   ⚠️This is final opportunity to verify timing before cover conceals components. Misalignment will cause immediate engine damage on startup.
10. 10

    Install timing cover with new gasket
    Apply thin bead of appropriate RTV silicone to block-to-oil pan sealing surface at bottom of timing cover if specified by gasket instructions. Position new timing cover gasket on block alignment dowels. Carefully align timing cover over dowels and press into position. Install all timing cover bolts in their original locations and hand-tighten. Torque timing cover bolts to specification in sequence from center outward to avoid gasket distortion.
11. 11

    Remove alignment tools and install crankshaft components
    Carefully remove camshaft alignment tools from cylinder heads through access holes. Remove crankshaft holding tool if installed. Clean crankshaft snout and apply small amount of clean engine oil. Install crankshaft pulley/harmonic balancer onto crankshaft ensuring keyway aligns properly. Install and torque crankshaft center bolt to manufacturer specification (typically 150+ Nm but verify in service manual).
12. 12

    Reinstall accessory components
    Reinstall thermostat housing with new gasket/O-ring and torque bolts to specification. Reconnect coolant hoses and install new clamps torqued to specification. Reinstall A/C compressor, alternator, and power steering pump to their mounting brackets and torque fasteners to specification. Route and install new accessory drive belt according to belt routing diagram on fan shroud.
    Torque spec

    Thermostat Housing Bolts15 Nm (11 lb-ft)

    Hose Clamps3 Nm (2 lb-ft)
13. 13

    Refill coolant system
    Close radiator drain valve. If equipped with coolant vacuum fill tool, attach to coolant reservoir and draw vacuum per tool instructions, then open coolant container to fill system. Without vacuum tool, slowly fill cooling system through radiator cap opening with Motorcraft Orange Coolant until full. Fill coolant reservoir to COLD FILL line. Start engine and allow to reach operating temperature with heater on maximum heat. Watch for leaks around water pump and timing cover. Add coolant as level drops due to air purging. When engine reaches operating temperature and upper radiator hose is hot, coolant level should stabilize.
    ⚠Monitor engine temperature closely during initial startup. If temperature rises above normal or coolant leaks appear, shut down immediately and investigate.

Reassembly

1. Reinstall engine cover by aligning clips and pressing down firmly until seated
2. Reinstall lower splash shields and any cross-braces removed for access
3. Reconnect negative battery cable to terminal
4. Lower vehicle from jack stands
5. Top off coolant reservoir to COLD FILL line after engine has cooled completely

Verification

• Start engine and verify no coolant leaks from water pump, timing cover, or hose connections
• Allow engine to reach full operating temperature (thermostat opening around 195°F) and verify cooling fan operation
• Check that heater produces hot air indicating proper coolant circulation
• Verify coolant level remains stable in reservoir after purging air from system
• Check engine oil dipstick after test drive - oil should remain clean with no milky appearance or overfill indicating coolant intrusion
• Listen for any abnormal timing chain noise that might indicate incorrect assembly or alignment
• After 50-100 miles, recheck coolant level and inspect for any seepage around timing cover gasket and water pump

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