I have a 1991 Volvo 940 Turbo with about 240K on the engine.The water pump was leaking. I drained the coolant by removing the lower radiator hose. I replaced the old water pump (for the first time) with a Hepu pump, removed old gasket material from block area, cleaned the thermostat housing of calcified corrosion, reconnected all coolant hoses, etc, and filled the reservoir with anti freeze. I started the car to check for leaks. No leaks from hoses. But during the idle process of about ten plus minutes (from engine start) I noticed that the temp gauge had climbed into the red. I checked the hoses and engine bay and realized that the top left of the pump where the rubber hat gasket fits was leaking oil at a good clip. Then I shut of the engine. Does this indicate a head gasket leak from possible over heating? or something else. Thank you for any input.

totally depends on year make and model. Let me know and I could help

4 Cylinder Thermostat Removal

1. Drain the coolant by opening the drain cock or removing the lower radiator hose. Remove the lid to speed up process

2. Remove the throttle body cover on turbo cars

3. Remove the bypass hose and the pressure pipe between the Intercooler and the throttle body on turbo cars

4. Rempve the screw that holds the coolant pipe to the water pump

5. Remove the screw that holds the coolant pipe in the front left of the engine

6. Remove the hose to the throttle body pre-heater

7. Remove the thermostat housing and remove the thermostat

8. Refit in Reverse

Hello. Here a non-photo diagram. Hope this helps!!!

The thermostat is located on the side of the water pump, the water pump is located just above the a/c compressor, the thermostat is fed coolant from the radiators lower radiator hose.
Thermostat :
1. drain coolant and tighten drain plug ( easier method : remove radiator cap, get big drain pan, place drain pan under lower radiator hose to radiator connection, remove clamp, slowly remove hose, allow coolant to drain into pan, now is a good time to remove radiator hose and clamp from thermostat housing )
2. remove thermostat cover / cap ( easiest to get at this when front of car is supported by jack stands and right hand side lower cover is removed ).
3. thermostat cap is held on by 3 bolts / remove thermostat.

You will notice that the thermostat's air bleed hole is pointing up and lines up with notch in water pump housing,,

ATTENTION :failure to install new thermostat in the correct location will cause engine to overheat.

1. install new thermostat to water pump, make sure air bleed hole lines up with notch, install and tighten bolts, install a new lower radiator hose, fill cooling system.

thermostat # 17670-77E00
lower radiator hose #17854-65G20
hose clamp #09401-36403
upper radiator hose # 17852-65G20

Suzuki factory manual

Instructions

1. 4.0L Explorer Engines
   • 1Place a drain pan underneath the radiator. When the engine is cool, drain the cooling system from the radiator into the pan.
     
   • 2Remove the fan shroud, the cooling fan, the accessory drive belt and the water pump pulley with the bolts.
     
   • 3Disconnect the coolant bypass hose and the lower radiator hose.
     
   • 4Loosen and remove the bolts attaching the water pump and remove the pump from the engine.
     
   • 5Clean all the mounting surfaces to the water pump.
     
   • 6Install the new pump, tightening the bolts to 89 inch pounds (20 to 28 Nm).
     
   • 7Reattach and install all components in reverse order from removal. Tighten the water pump pulley bolts to 18 foot pounds (25 Nm).
     
   • 8Refill the cooling system. Start the car and check for leaks when the engine reaches normal operating temperature.
     
   5.0L Explorer Engines
   • 9Disconnect the negative battery cable and place a drain pan underneath the radiator. When the engine is cool, drain the cooling system from the radiator into the pan.
     
   • 10Remove the fan shroud, the cooling fan, the accessory drive belt and the water pump pulley with the bolts.
     
   • 11Take out the accessory drive belt. Disconnect and remove the heater hose and the bypass hose from the pump.
     
   • 12Remove the brackets to the engine control sensor wiring. Move the harness out of the way.
     
   • 13Loosen and remove the bolts to the water pump pulley and the water pump and remove the pulley.
     
   • 14Pull the water pump out and away from the front cover. Once the water pump is out of the way, disconnect the lower radiator hose. Then, take the water pump out of the engine.
     
   • 15Clean the front cover to the water pump and all the mounting surfaces. Put some adhesive gasket sealer on both sides of a brand new gasket and put it on the pump.
     
   • 16Reattach the lower radiator hose to the pump and reattach the pump, tightening the bolts to 15 to 21 foot pounds (20 to 28 Nm).
     
   • 17Reattach and reinstall all components in reverse order to their removal.
     Reattach the negative battery cable and refill the cooling system. Start the car and check for leaks when the engine reaches normal operating temperature.
     

Water Pump REMOVAL & INSTALLATION 2.3L and 2.5L Engines Fig. 1: Exploded view of the water pump and related parts for the 2.3L and 2.5L engine

1. Disconnect the negative battery cable.
2. Drain the cooling system. CAUTION
   When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.
   
3. Remove the two bolts that retain the fan shroud and position the shroud back over the fan.
4. Remove the four bolts that retain the cooling fan. Remove the fan and shroud.
5. Loosen and remove the accessory drive belt. Earlier models may have two drive belts, remove them both.
6. Remove the water pump pulley and, if necessary, the vent hose to the emissions canister.
7. Remove the heater hose at the water pump.
8. Remove the timing belt cover. Remove the lower radiator hose from the water pump.
9. Remove the water pump mounting bolts and the water pump. Clean all gasket mounting surfaces.
10. Install the water pump in the reverse order of removal. Coat the threads of the mounting bolts with sealer before installation.

2.9L Engines

1. Drain the coolant from the radiator and remove the lower hose and the return hose from the water inlet housing. CAUTION
   When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.
   
2. Using Tools T83T-6312-A and B remove the fan and clutch assembly from the front of the water pump. NOTE: See the engine fan removal procedure in this section.
   
3. Loosen the alternator mounting bolts and remove the alternator belt.
4. Remove the water pump pulley.
5. Remove the bolts retaining the water pump assembly and remove the water pump, water inlet housing, and the thermostat from the front cover.
6. Before installing the water pump, clean the gasket surfaces on the front cover and on the water pump assembly. Apply gasket sealer to both sides of the new gasket and install the water pump in the reverse order of removal.

3.0L Engine

1. Disconnect the battery ground cable.
2. Drain the cooling system. CAUTION
   When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.
   
3. Remove the engine fan.
4. Loosen the 4 water pump pulley bolts.
5. Remove the accessory drive belts. Fig. 2: Exploded view of the 3.0L engine water pump
   
   
6. Remove the water pump pulley.
7. Remove the alternator adjusting arm and throttle body brace.
8. Remove the lower radiator hose.
9. Disconnect the heater hose at the pump.
10. Rotate the belt adjuster out of the way.
11. Remove the water pump attaching bolts. Note their location for installation.
12. Remove the pump and discard the gasket.
13. Thoroughly clean the pump and engine mating surfaces. To install:
    
14. Using an adhesive type sealer, position a new gasket on the timing cover.
15. Position the water pump and start the bolts. When all the bolts are started, torque them to specifications. Refer to the necessary illustration. Fig. 3: 3.0L engine water pump and front cover fastener chart
    
    
16. Install the lower hose and connect the radiator hose.
17. Install the pulley and hand-tighten the 4 bolts.
18. Install the alternator adjusting arm and brace.
19. Install the belts and tension them. See Section 1.
20. Tighten the 4 pulley bolts to 19 ft. lbs.
21. Install the fan.
22. Fill and bleed the cooling system.
23. Connect the battery ground cable. Run the engine and check for leaks.

COULD BE A BAD WATER PUMP.OR STOP UP RADIATOR CORES.TRY FLUSHING OUT RADIATOR.AND FLUH OUT ENGINE REMOVE THERMOSTAT.FLUSH ENGINE WITH A GARDEN HOSE THROUGH WATER PUMP UNTIL FLOW OUT TOP RADIATOR UNTIL YOU SEE CLEAR WATER.REMOVE ANTIFREEZE FIRST.DRAIN OUT ANTIFREEZE IN A DRAIN PAN PUT IN A SAFE PLACE AWAY FROM CHILDERN AND PETS.FLUSH OUT ENGINE I WOULD REPLACE WATER PUMP ALSO SEE WHAT HAPPENS.

REMOVAL & INSTALLATION
2.0L Engine

1. Disconnect the negative battery cable.

CAUTION Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant.

1. Drain the engine cooling system.
2. Raise and safely support the vehicle.
3. Remove the lower radiator hose from the water pump.

If the lower radiator hose is hard to reach on the back of the water pump, remove the hose at the radiator and after the water pump is ready to be removed, pull the water pump away from the engine block until there is enough room to remove the hose from the pump.

1. Lower the vehicle.
2. Remove the accessory drive belt.
3. Remove the timing belt covers and the timing belt as outlined in this Section.
4. Remove the four water pump retaining bolts.
5. Remove the water pump.
   

To install:

1. Thoroughly clean all sealing surfaces.
2. Install a new water pump gasket and the water pump onto the cylinder block.
3. Tighten the retaining bolts to 12-15 ft. lbs. (16-20 Nm).
4. Reinstall the timing belt and the timing belt covers as outlined in this Section.
5. Reinstall the accessory drive belt.
6. Raise and safely support the vehicle.
7. Reinstall the lower radiator hose.
8. Lower the vehicle.
9. Fill the engine cooling system.
10. Reconnect the negative battery cable.
11. Start the engine and top off the coolant as necessary. Check for leaks.

2.5L Engine

Before continuing with this procedure, be sure three new water pump retaining bolts (W701544) are available. Due to their torque-to-yield design, the bolts stretch and cannot be reused.

1. Disconnect the negative battery cable.

CAUTION Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant.

1. Drain the engine cooling system.
2. Remove the water pump pulley shield.
3. Remove the water pump drive belt.
4. Remove the water pump inlet and outlet hoses from the water pump.
5. Remove the three water pump to left cylinder head retaining bolts.
6. Remove the water pump and water pump housing from the vehicle.
7. Remove the water pump to water pump housing retaining bolts and separate the water pump from the water pump housing.

To install:

1. Thoroughly clean all sealing surfaces.
2. Install the water pump to the water pump housing using a new gasket and install the retaining bolts. Tighten the retaining bolts to 16-18 ft. lbs. (22-25 Nm).
3. Position the water pump and water pump housing and install three new torque-to-yield retaining bolts into the left cylinder head.
4. Tighten the new retaining bolts to 11-13 ft. lbs. (15-18 Nm), then rotate the retaining bolts 85-95 degrees.
5. Reinstall the water pump inlet and outlet hoses to the water pump.
6. Reinstall the water pump drive belt.
7. Reinstall the water pump shield.
8. Fill the engine cooling system.
9. Reconnect the negative battery cable.
10. Start the engine and top off the coolant as necessary. Check for leaks.

Hope helps (remember comment and rated this).

BUY YOUR RADIATOR HOSES FIRST MAKE SURE NEW HOSES MATCH THE OLD HOSES. BUY NEW RADIATOR CLAMPS AND HAVE EXTRA GALLON OF ANTIFREEZE. MAKE SURE ENGINE IS COOL IF YOU GOING TO CHANGE TOP RADIATOR HOSE REMOVE RADIATOR CAP OR OVER FLOW JUG CAP IF YOUR RADIATOR DONT HAVE RADIATOR CAP FIND RADIATOR DRAIN PLUG.PLACE A CATCH PAN.OPEN RADIATOR DRAIN PLUG CATCH ANTIFREEZE. DRAIN HALF ANTIFEEZE IF YOU GOING TO REPLACE TOP HOSE AND DRAIN OUT ALL ANTIFREEZE IF YOU GOING TO CHANGE LOWER COOLANT HOSE TO WATER PUMP.WHEN DONE CLOSE DRAIN PLUG.PUT ANTIFREEZE IN A SAFE PLACE FROM PETS AND KIDS UNTIL JOB DONE. WHEN YOU REMOVE COOLANT REMOVE WATER HOSE CLAMPS THEN REMOVE RADIATOR HOSES PUT NEW RADIATOR HOSES AND CLAMPS ON HOSES TIGHTEN HOSE CLAMPS DONT OVER TIGHTEN. POUR ANTIFREEZE IN RADIATOR.CRANK ENGINE UP CHECK FOR LEAKS.CHECK COOLANT LEVEL WHEN THERMOSTAT OPENS ADD MORE COOLANT AS NEEDED.

Ford Pick-Ups/Bronco 1976-1986 Repair Guide Water Pump - REMOVAL & INSTALLATION

6-300 Engines

1. Drain the cooling system.
   

CAUTION When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

1. Disconnect the lower radiator hose from the water pump.
2. Remove the drive belt, fan, fan spacer, fan shroud, if so equipped, and water pump pulley.
3. Remove the alternator pivot arm from the pump.
4. Disconnect the heater hose at the water pump.
5. Remove the water pump.
6. Before installing the old water pump, clean the gasket mounting surfaces on the pump and on the cylinder block. If a new water pump is being installed, remove the heater hose fitting from the old pump and install it on the new one. Coat the new gaskets with sealer on both sides and install the water pump in the reverse order of removal. Torque the mounting bolts to 14-18 ft. lbs.
   

V6-3.8L Engines
See Figures 1 and 2



Fig. 1: V6 water pump installation



Fig. 2: V6 water pump bolt torque sequence

1. Drain the cooling system.
   

CAUTION When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

1. Remove the air cleaner.
2. Remove the bolts securing the fan shroud to the radiator, if so equipped, and position the shroud over the fan.
3. Disconnect the lower radiator hose, heater hose and by-pass hose at the water pump. Remove the drive belts, fan, fan spacer and pulley. Remove the fan shroud, if so equipped.
4. Loosen the alternator pivot bolt and the bolt attaching the alternator adjusting arm to the water pump. Remove the power steering pump bracket from the water pump and position it out of the way.
5. If necessary, remove the air conditioner compressor and bracket. The refrigerant lines should remain connected.
6. Remove the bolts securing the water pump to the timing chain cover and remove the water pump.
7. Thoroughly clean the mounting surfaces of all gasket material.
8. Install the water pump in the reverse order of removal, using a new gasket. Torque the bolts to 15-22 ft. lbs. in the sequence shown.

8-360, 390

1. Drain the cooling system.
   

CAUTION When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

1. Remove the bolts securing the fan shroud to the radiator, if so equipped, and position the shroud over the fan.
2. Disconnect the lower radiator hose, heater hose and by-pass hose at the water pump. Remove the drive belts, fan, fan spacer and pulley. Remove the fan shroud, if so equipped.
3. Loosen the alternator pivot bolt and the bolt attaching the alternator adjusting arm to the water pump. Remove the power steering pump bracket from the water pump and position it out of the way.
4. If necessary, remove the air conditioner compressor and bracket. The refrigerant lines should remain connected.
5. Remove the bolts securing the water pump to the timing chain cover and remove the water pump.
6. Install the water pump in the reverse order of removal, using a new gasket. Torque the bolts to 20-25 ft. lbs.

8-351M, 400, 460

1. Disconnect the battery ground.
2. Drain the cooling system.
   

CAUTION When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

1. Remove the bolts securing the fan shroud to the radiator, if so equipped, and position the shroud over the fan.
2. Remove the fan assembly.
3. Remove the fan shroud.
4. Remove the accessory drive belts and water pump pulley.
5. Remove the alternator and brackets.
6. Remove the compressor and bracket and lay it aside. DO NOT disconnect the refrigerant lines!
7. Remove the power steering pump and brackets. Lay it aside. DO NOT disconnect the fluid lines!
8. Disconnect the heater hose and lower radiator hose from the pump.
9. Remove the bolts securing the water pump to the engine and lift off the water pump.
10. Clean all gasket mounting surfaces thoroughly.
    

To install:

1. Install the water pump in the reverse order of removal, using a new gasket coated with sealer. Torque the bolts to 12-18 ft. lbs.
2. Install all remaining parts in reverse order. Fill the cooling system, start the engine and check for leaks.

continue...

You can change the water pump by doing these steps:

• With the engine off and cold, o pen the hood and locate the vehicle’s radiator and water pump.
• Remove the radiator cap.
• Install a pressure tester on the radiator. Apply the pressure indicated on the radiator cap or in the owner’s manual.
• Inspect the water pump for leaks. Remove the pressure tester.
• Place a drain pan under the radiator. Open the drain valve or remove the lower radiator hose to drain the cooling system.
• Remove the drive belts or serpentine belt.
• Remove any hoses connected to the water pump.
• Unbolt the water pump from the engine. Remove the water pump.
• Using a gasket scraper, clean the mounting surface on the engine block.
• Install a new gasket and attach the new water pump to the engine with the original mounting bolts. Tighten the bolts to the manufacturer’s specifications.
• Re-install any hoses and belts that were removed.
• Re-install the drain plug or lower radiator hose.
• Refill the radiator with a 50/50 mix of coolant and distilled water. Pressure test the cooling system and check for leaks.
• Check and fill the overflow reservoir with coolant.
• Leave the radiator cap off and start the engine. Idle the engine to remove trapped air from the cooling system. Add coolant if necessary.
• Install the radiator cap.
• Road test the vehicle and monitor the temperature gauge. If the vehicle runs hot, there may be an air pocket in the cooling system. Allow the engine to cool off and add the necessary coolant.