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Place a drain pan underneath the radiator. When the engine is cool, drain the cooling system from the radiator into the pan.
2
Place a car jack underneath the oil pain to support it. Also, to protect the engine parts, put a block of wood onto the jack.
3
Disconnect the negative battery cable and remove the engine mount and bracket on the right side.
4
Take out the drive belts as well as the idler pulley bracket, the chain tensioner cover and the water pump cover.
5
Push the timing chain tensioner sleeve up and put a stopper pin in it to keep it from slipping. Take out the chain tensioner assembly.
6
Turn the crankshaft pulley in a backward motion until it rotates 20 degrees.
7
Place 2 MB bolts into the threaded holes of the pump and tighten them by hand, alternating turning a half turn each at a time unit they reach the timing chain rear case. Doing it this way will prevent damage to the timing chain rear case.
8
Remove the water pump, throwing away the old o-rings. Make sure not to let the water pump hit the timing chair.
Install the New Water Pump
1
Clean all the mounting surfaces on the water pump and covers.
2
Install the new water pump with the new o-rings, tightening the bolts to 75 to 95 inch pounds (8.5 to 10.7 Nm).
3
Turn the crankshaft pulley back to its starting position (20 degrees forward).
4
Install the chain tensioner and water pump covers, tightening to .092 to 130 inch pounds (2.3 to 3.3 mm).
5
Take out the stopper pin from the timing chain tensioner.
6
Put a bead of liquid sealant onto the mating surfaces of the water pump and timing chain tensioner.
7
Install the timing chain tensioner with the water pump to the engine block, tightening the bolts to 87 to 113 inch pounds.
8
Add the drive belts, the idler pulley bracket and the engine mounting bracket with the engine mount.
9
Reinstall the negative battery cable and remove the jack from under the engine. Install drain plugs to the cylinder block.
10
Start the car and check for leaks when the engine reaches normal operating temperature.
Continue to monitor for the next few days for air bubbles in the system causing the fluid level to go down. NEVER TOUCH A HOT ENGINE, CHECK WHEN ENGINE IS COOL. Good luck! --My Car Doc
Replacing the water pump on my 2004 5.9 cummins 1ton Dually was easy,Disconnect neg. batt. cables, drain coolant,released serpentine belt tensioner with 1/2" drive ratchet and while in released position slipped belt from ac compressor,removed two bolts that held alt. to brackets, slipped alt. to one side then removed upper alt. brkt., removed two bolts on water pump, made sure mounting surface of block was clean and took new water pump put a small amt. of rtv sealant all around groove that rubber seals goes in,install rubber seal, "be sure and wipe off excess sealant then re-install water pump tightening carefully,reinstall alt. upper brkt., then alt. put belt back in correct position but be sure and leave it off of ac pulley so you can reinstall it on ac when you are underneath the eng. area while releasing tension on belt tensioner. Fill with proper coolant type till you have rad. full. Reinstall cables, start eng and with cap off you will have to add coolant as eng. warms up till it has air out of system. Once rad. is full install cap then refill coolant recovery bottle to full level, Keep and eye on it for leaks for a couple of days and "Happy Driving" Don't think I left anything out :)
Water Pump - REMOVAL & INSTALLATION 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. 3.4L ENGINE (see Figures 1 and 2)
Disconnect the negative battery cable.
Drain the cooling system into a suitable container.
Remove the air intake duct.
Remove the top coil of the ignition coil pack.
Loosen the tensioner pulley bolt/screw.
Disconnect the heater hose from the water pump.
Loosen the water pump pulley bolts/screws.
Unfasten the power steering bracket bolts/screws.
Remove the serpentine drive belt.
Remove the water pump pulley.
Remove the power steering pump bracket and swing the bracket and
pump aside. Do NOT disconnect the power steering lines from the pump.
Unfasten the water pump and engine front cover bolts/screws, then
remove the water pump assembly from the vehicle.
Remove and discard the gasket and thoroughly clean the gasket
mating surfaces.
Fig. 1: Exploded view of the water pump mounting - 3.4L
engine To install:
Position a new water pump gasket, then install the pump. Secure
using all of the water pump retaining bolts/screws, except the bottom
three, and tighten to 33 ft. lbs. (45 Nm).
Install the engine front cover bolts/screws and tighten to 16 ft.
lbs. (21 Nm) for 1993-94 vehicles, or to 97 inch lbs. (11 Nm) for 1995
vehicles.
Fig. 2: Water pump retaining bolt tightening sequence
Install the three bottom water pump retaining screws and tighten
to 89 inch lbs. (10 Nm).
Place the power steering pump into position and install the pump
bracket.
Install the water pump pulley.
Install the serpentine drive belt.
Install the power steering pump bracket retaining bolts and
tighten to 30 ft. lbs. (40 Nm).
Connect the heater hose to the water pump.
Install the top coil to the ignition coil pack.
Attach the electrical connector to the alternator.
Install the air inlet duct and air cleaner assembly.
Connect the negative battery cable.
Fill the cooling system. Start the engine and check for leaks.
3.8L Engine
Disconnect the negative battery cable.
Drain the cooling system into a suitable container.
Remove the serpentine belt.
Disconnect the radiator inlet hose from the water pump.
Unfasten the water pump pulley bolts/screws and remove the pulley.
Remove the water pump pulley retaining bolts, then remove the pump
from the vehicle.
Remove and discard the gasket and thoroughly clean the gasket
mating surfaces
To install:
Position a new water pump gasket, then install the pump. Secure
using the water pump retaining bolts/screws and tighten to 11 ft. lbs.
(15 Nm), plus an additional 80 degree rotation.
Install the water pump pulley and retaining bolts. Tighten to 115
inch lbs. (13 Nm).
Install the serpentine drive belt.
Connect the radiator inlet hose to the water pump.
Connect the negative battery cable.
Fill the cooling system. Start the engine and check for leaks.
5.7L ENGINE
Unplug the electrical connector from the cooling fan.
For 1993-95 vehicles, remove the right side cooling fan.
For 1996-98 vehicles, remove both cooling fan assemblies.
Place a suitable drain pan under the vehicle, then remove the
block coolant drain plug and the knock sensor. Drain the radiator.
Install the drain plug and knock sensor.
Remove the air intake duct and air cleaner.
Disconnect the upper and lower radiator hoses from the water pump.
Remove the heater hoses from the water pump and throttle body.
Unplug the electrical connector from the coolant sensor.
Unfasten the retainers and reposition the ignition coil and
bracket.
If equipped, remove the air pump and bracket.
Unfasten the water pump attaching bolts, then remove the water
pump and discard the gasket. Remove the shaft coupling and water pump
driveshaft seals, if necessary.
Thoroughly clean the gasket mating surfaces
To install:
If removed, install the shaft coupling and water pump driveshaft
using J 39089 or equivalent water pump driveshaft O-ring installer.
Install the water pump with a new gasket. Tighten the bolts to
30-32 ft. lbs. (41-43 Nm).
If equipped, install the air pump and bracket.
Reposition and secure the ignition coil and bracket.
Attach the coolant sensor connector.
Connect the heater hoses to the water pump and throttle body.
Connect the upper and lower radiator hoses to the water pump.
Install the air cleaner and air inlet duct.
Install the electric cooling fan(s), then attach the electrical
connector.
Refill the cooling system.
Connect the negative battery cable, then start the engine and
check for leaks.
Step 1
Drain the antifreeze from cooling system. Remove belt from
water pump. Examine and see if you have to remove anything else to get
out the water pump. If so make a diagram of everything you are removing
so you can put it back together.
Step 2
Remove the hoses from the water pump. Find all bolts holding
the water pump in . Loosen each one a little bit. After all are lose
you can then remove them. Remove water pump. Put new gasket on and
install new water pump. Hook up hoses to water pump. Look at your
diagram and replace everything you had to remove earlier. Put the belt
back on.
Step 3
Shut the drain on system and refill cooling system. Make sure
you use the antifreeze that is designed for system. Run engine for a
couple of minutes. Check for leaks and check coolant level. Add if
necessary. If there is no leaks you are ready to go.
Short of buying a haynes or chilton manual. the basic instructions are, remove anything that is in your way. fan, fan shroud and brackets. Buy the new pump before starting and place it flat on a piece of cardboard. Use a magic marker and trace it's outline and punch holes through all bolt holes. As you remove bolts from pump, put each through it's corresponding hole. Make sure you make note of any spacers and bracket locations. Once the pump is off make sure that you remove every bit of old gasket material before putting pump back on. Generally it's best to use silicone sealer on at least the pump surface and place the gasket on the pump, waiting 'till its nearly dry before installing (keeps it from moving around while you are working) I also put a thin film of silicone on engine side of gasket just before putting it on. When replacing bolts, snug them finger tight only 'till they are all in. any bolts that will be covered by a bracket need to be tightened first before installing bracket. If you took good notes, the job should not be too difficult. Only change your pump for the right reasons: If the pump is leaking or the shaft bearing is loose and or the bearing is noisy. Changing the pump for any other reason is a waste of time and money. replacing a pump that is not leaking will not cure an overheat problem. good luck....any problems, just ask.
I am sure the leak is the water pump based on years of Escort work, The ZX2 is equipped with a 2.0L DOHC V-Tech engine. The water pump is on the front (rt side of car) of the engine block, visible with the hood up. NAPAautoparts replacement instructions are to loosen the belt drive pulley from the pump BEFORE removing the serpentine belt. Once the four bolts are loose, take the belt off (good time to replace?) remove bolts and old water pump (four more bolts)- it will be tight, but it comes out- clean gasket area and install new gasket and pump in reverse order. That includes putting the pulley on and hand tightening the bolts, put on the belt, finish tightening the bolts to the pulley.
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