1991 1999 ford explorer chilton User Manual

							
REMOVAL & INSTALLATION
2.3L and 2.5L Engines
Exploded view of the water pump and related parts for the 2.3L and 2.5L engine Click to enlarge
Disconnect the negative battery cable.
1. 
Drain the cooling system.
2. 
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 HOW TO USE THIS BOOK
324 REMOVAL & INSTALLATION 
						

							
sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is
contaminated or is several years old.
Remove the two bolts that retain the fan shroud and position the shroud back over the fan.
3. 
Remove the four bolts that retain the cooling fan. Remove the fan and shroud.
4. 
Loosen and remove the accessory drive belt. Earlier models may have two drive belts, remove them
both.
5. 
Remove the water pump pulley and, if necessary, the vent hose to the emissions canister.
6. 
Remove the heater hose at the water pump.
7. 
Remove the timing belt cover. Remove the lower radiator hose from the water pump.
8. 
Remove the water pump mounting bolts and the water pump. Clean all gasket mounting surfaces.
9. 
Install the water pump in the reverse order of removal. Coat the threads of the mounting bolts with
sealer before installation.
10. 
2.9L Engines Drain the coolant from the radiator and remove the lower hose and the return hose from the water
inlet housing.
1. 
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.
Using Tools T83T-6312-A and B remove the fan and clutch assembly from the front of the water
pump.
2. 
See the engine fan removal procedure in this section. Loosen the alternator mounting bolts and remove the alternator belt.
3. 
Remove the water pump pulley.
4. 
Remove the bolts retaining the water pump assembly and remove the water pump, water inlet
housing, and the thermostat from the front cover.
5. 
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.
6. 
3.0L Engine Disconnect the battery ground cable.
1. 
Drain the cooling system.
2. 
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.
Remove the engine fan.
3. 
Loosen the 4 water pump pulley bolts.
4. 
Remove the accessory drive belts.
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REMOVAL & INSTALLATION 325 
						

							Exploded view of the 3.0L engine water pump
Click to enlarge
Remove the water pump pulley.
6. 
Remove the alternator adjusting arm and throttle body brace.
7. 
Remove the lower radiator hose.
8. 
Disconnect the heater hose at the pump.
9. 
Rotate the belt adjuster out of the way.
10. 
Remove the water pump attaching bolts. Note their location for installation.
11. 
Remove the pump and discard the gasket.
12. 
Thoroughly clean the pump and engine mating surfaces.
13. 
To install: Using an adhesive type sealer, position a new gasket on the timing cover.
14. 
Position the water pump and start the bolts. When all the bolts are started, torque them to
specifications. Refer to the necessary illustration.
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326 REMOVAL & INSTALLATION 
						

							3.0L engine water pump and front cover fastener chart
Click to enlarge
Install the lower hose and connect the radiator hose.
16. 
Install the pulley and hand-tighten the 4 bolts.
17. 
Install the alternator adjusting arm and brace.
18. 
Install the belts and tension them. See Section 1.
19. 
Tighten the 4 pulley bolts to 19 ft. lbs.
20. 
Install the fan.
21. 
Fill and bleed the cooling system.
22. 
Connect the battery ground cable. Run the engine and check for leaks.
23. 
4.0L Engine (VIN X) Disconnect the negative battery cable.
1. 
Drain the cooling system.
2. 
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. HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 327 
						

							To service the water pump, first drain the cooling system, then remove the engine fan/clutch ...
... and the fan shroud from the vehicle
Remove the fan and fan clutch assembly.
3. 
See the engine fan removal procedure in this section. HOW TO USE THIS BOOK
328 REMOVAL & INSTALLATION 
						

							Remove the lower radiator hose from the water pump. Position a drain pan underneath to catch
any coolant
Remove the lower radiator hose from the water pump.
4. 
On 1997-99 Explorer/Mountaineer models, remove the radiator.
5. 
Loosen the water pump pulley attaching bolts ...... before removing the accessory drive belt ...
Loosen the water pump pulley attaching bolts.
6. 
Except 1997-99 Explorer/Mountaineer models, loosen the alternator mounting bolts and remove the
belt. On vehicles with air conditioning, remove the tensioner pulley, alternator and bracket.
7. 
Except 1997-99 Explorer/Mountaineer models, remove the A/C compressor and power steering
pump mounting bracket, without disconnecting the lines, and set off to the side.
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REMOVAL & INSTALLATION 329 
						

							... then with the drive belt out of the way, finish removing the water pump pulley
Remove the water pump pulley.
9. 
Disconnect the heater hose at the pump.
10. 
Remove the heater hose connection at the water pumpRemove all of the water pump attaching bolts ... HOW TO USE THIS BOOK
330 REMOVAL & INSTALLATION 
						

							... then remove the pump from the engine
Remove the attaching bolts and remove the water pump.
11. 
To install: Clean the mounting surfaces of the pump and front cover thoroughly. Remove all traces of gasket
material.
12. 
Remove all traces of the old gasket before installing the pump
Apply adhesive gasket sealer to both sides of a new gasket and place the gasket on the pump.
13. 
Position the pump on the cover and install the bolts finger-tight. When all bolts are in place, torque
them to 72-108 inch lbs. (8.5-12 Nm).
14. 
Install the pulley.
15. 
On vehicles with air conditioning, install the alternator, bracket and tensioner pulley.
16. 
Install the A/C compressor and power steering pump mounting bracket.
17. 
Install and adjust the drive belt.
18. 
Connect the hoses and tighten the clamps.
19. 
Install the fan and clutch assembly.
20. 
Fill and bleed the cooling system.
21. 
Connect the negative battery cable, then start the engine and check for leaks.
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4.0L SOHC Engine (VIN E)
Disconnect the negative battery cable.
1. 
Drain the cooling system.
2. 
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.
Remove the fan and fan clutch assembly.
3. 
See the engine fan removal procedure in this section. Remove the radiator.
4. 
Loosen the water pump pulley attaching bolts.
5. 
Remove the accessory drive belt and the idler pulley.
6. 
Slide the bypass hose clamp back, away from the pump.
7. 
Disconnect the heater hose at the pump.
8. 
Remove the lower radiator hose.
9. 
Remove the water pump pulley.
10. 
Remove all of the water pump attaching bolts. Pay attention to the locations of any stud bolts.
11. 
Remove the water pump.
12. 
To install: Clean the mounting surfaces of the pump and front cover thoroughly. Remove all traces of gasket
material.
13. 
Apply adhesive gasket sealer to both sides of a new gasket and place the gasket on the pump.
14. 
Position the pump on the cover, while connecting the bypass hose to the pump, and install the bolts
finger-tight. When all bolts are in place, torque them to 72-108 inch lbs. (6-9 ft. lbs. or 8.5-12 Nm).
15. 
Position the bypass hose clamp back to its original position.
16. 
Install the water pump pulley and its attaching bolts. Snug the bolts.
17. 
Connect the lower radiator and heater hoses to the water pump.
18. 
Install the belt idler pulley.
19. 
Lift the accessory drive belt tensioner and install the belt.
20. 
Securely tighten the water pump pulley attaching bolts.
21. 
Install the radiator and the engine fan.
22. 
Refill and bleed the cooling system.
23. 
Connect the negative battery cable, start the engine and check for leaks.
24. 
5.0L Engine Disconnect the negative battery cable.
1. 
Drain the cooling system.
2. 
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.
Remove the fan/clutch assembly and shroud.
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332 REMOVAL & INSTALLATION 
						

							
See the engine fan removal procedure in this section.
Loosen the water pump pulley attaching bolts.
4. 
Remove the accessory drive belt.
5. 
Remove the water bypass hose from the pump.
6. 
Disconnect the heater hose at the pump.
7. 
Remove the engine control sensor wiring harness brackets and position the harness out of the way.
8. 
Remove the water pump pulley.
9. 
Exploded view of the 5.0L water pumpClick to enlarge
Remove all of the water pump attaching bolts. Pay attention to the locations of any stud bolts.
10. 
Pull the water pump away from the front cover, then disconnect the lower radiator hose from the
pump
11. 
Lift the water pump from the vehicle.
12. 
To install: Clean the mounting surfaces of the pump and front cover thoroughly. Remove all traces of gasket
material.
13. 
Apply adhesive gasket sealer to both sides of a new gasket and place the gasket on the pump.
14. 
Install the lower radiator hose to the water pump.
15. 
Position the pump on the cover and install the bolts finger-tight. When all bolts are in place, torque
them to 15-21 ft. lbs. (20-28 Nm).
16. 
Position the engine control sensor wiring harness and install the retaining nuts.
17. 
Install the water pump pulley and its attaching bolts. Snug the bolts.
18. 
Install the heater and water bypass hoses to the water pump.
19. 
Lift the accessory drive belt tensioner and install the belt.
20. 
Securely tighten the water pump pulley attaching bolts.
21. 
Install the engine fan/clutch assembly and the shroud.
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REMOVAL & INSTALLATION 333