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    Ford Mustang 1999-2005

    Removal & Installation

    Print

    3.8L Engine



    1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
      2.  
    2. Drain the engine cooling system.
      3.  
    3. Remove electric cooling fan assembly.
      4.  
    4. Loosen water pump pulley bolts.
      5.  
    5. Remove the accessory drive belt.
      6.  
    6. Remove power steering pump pulley.
      7.  
    7. Remove water pump pulley.
      8.  
    8. Remove ignition coil and bracket, if necessary.
      9.  
    9. Remove power steering pump bracket.
      10.  
    10. Disconnect lower radiator hose from water pump.
      11.  
    11. Disconnect heater water outlet tube.
      12.  
    12. Remove water pump. Clean and inspect gasket mating surfaces.

      Click image to see an enlarged view

      Fig. Exploded view of the water pump mounting on the 3.8L engine-during removal, note the original positions of the different length bolts for reassembly



      Click image to see an enlarged view

      Fig. Water pump torque sequence-3.8L engine

      13.  

    To install:


    NOTE
    The threads of the No. 1 water pump retaining bolt must be coated with a Teflon® sealant prior to installation.

    1. Install water pump. Use a new gasket and tighten the bolts and studs to 15-22 ft. lbs. (20-30 Nm). Tighten the nuts to 71-106 inch lbs. (8-12 Nm).
      2.  
    2. Connect lower radiator hose.
      3.  
    3. Connect heater water outlet tube. Use a new O-ring seal and tighten the bolts to 71-106 inch lbs. (8-12 Nm).
      4.  
    4. Install power steering pump bracket.
      5.  
    5. Install ignition coil and bracket, if necessary.
      6.  
    6. Install water pump pulley. Tighten the bolts to 15-21 ft. lbs. (21-29 Nm).
      7.  
    7. Install power steering pump pulley.
      8.  
    8. Install water pump pulley. Tighten the bolts to 15-21 ft. lbs. (21-29 Nm).
      9.  
    9. Install the accessory drive belt.
      10.  
    10. Install electric cooling fan assembly.
      11.  
    11. Fill the cooling system.
      12.  
    12. Start the engine and check for coolant leaks.
      13.  

    4.0L Engine



    1. Drain the engine cooling system.
      2.  
    2. Remove the air cleaner outlet pipe.
      3.  
    3. Loosen water pump pulley bolts.
      4.  
    4. Remove the accessory drive belt.
      5.  
    5. Remove the water pump pulley.
      6.  
    6. Remove the upper and lower radiator hose.
      7.  
    7. Remove the heater hose.
      8.  
    8. Remove the 12 attaching bolt and remove the water pump. Clean and inspect gasket mating surfaces.

      Click image to see an enlarged view

      Fig. Exploded view of the water pump mounting-4.0L engine

      9.  

    To install:

    1. Install the water pump. Use a new gasket and tighten the bolts to 89 inch lbs. (10 Nm).
      2.  
    2. Install the heater hose.
      3.  
    3. Install the upper and lower radiator hose.
      4.  
    4. Install the water pump pulley.
      5.  
    5. Install the accessory drive belt.
      6.  
    6. Install water pump pulley bolts.
      7.  
    7. Install the air cleaner outlet pipe.
      8.  
    8. Fill the cooling system.
      9.  
    9. Start the engine and check for coolant leaks.
      10.  

    4.6L Engine



    1. Drain the engine cooling system.
      2.  
    2. Remove the air cleaner outlet pipe.
      3.  
    3. Loosen water pump pulley bolts.
      4.  
    4. Remove the accessory drive belt.
      5.  
    5. Remove the water pump pulley.
      6.  
    6. Remove the water pump.

      Click image to see an enlarged view

      Fig. Exploded view of the water pump mounting-4.6L engine

      7.  

    To install:

    1. Install water pump. Use a new O-ring seal and tighten the bolts to 18 ft. lbs. (25 Nm).
      2.  
    2. Install the water pump pulley and tighten the bolts to 18 ft. lbs. (25 Nm).
      3.  
    3. Install the accessory drive belt.
      4.  
    4. Install air cleaner outlet pipe.
      5.  
    5. Fill the cooling system.
      6.  
    6. Start the engine and check for coolant leaks.
      7.  

    Non-Supercharged
    1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
      2.  
    2. Remove air intake scoop, if equipped.
      3.  
    3. Drain the engine cooling system.
      4.  
    4. Remove electric cooling fan assembly.
      5.  
    5. Loosen water pump pulley bolts.
      6.  
    6. Remove the accessory drive belt.
      7.  
    7. Remove water pump pulley.
      8.  
    8. Remove water pump.

      Click image to see an enlarged view

      Fig. Exploded view of the water pump mounting-4.6L engines

      9.  

    To install:

    1. Install water pump. Use a new O-ring seal and tighten the bolts in a crossing pattern to 15-22 ft. lbs. (20-30 Nm).
      2.  
    2. Install water pump pulley. Tighten the bolts to 15-21 ft. lbs. (21-29 Nm).
      3.  
    3. Install the accessory drive belt.
      4.  
    4. Install electric cooling fan assembly.
      5.  
    5. Install air intake scoop, if equipped.
      6.  
    6. Fill the cooling system.
      7.  
    7. Start the engine and check for coolant leaks.
      8.  

    Supercharged
    1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
      2.  
    2. Drain the engine cooling system.
      3.  
    3. Drain the supercharger cooling system.
      4.  
    4. Remove nut and move wiring harness aside.
      5.  
    5. Remove stud and move coolant hose assembly aside.
      6.  
    6. Lower the vehicle.
      7.  
    7. Disconnect radiator hoses.
      8.  
    8. Remove top radiator shield.
      9.  
    9. Remove coolant recovery tank.
      10.  
    10. Remove supercharger drive belt cover.
      11.  
    11. Remove supercharger drive belt.
      12.  
    12. Remove supercharger cooling system hose.
      13.  
    13. Remove fasteners and move power steering reservoir aside.
      14.  
    14. Remove nut and move A/C muffler bracket aside.
      15.  
    15. Remove belt idler bracket support.
      16.  
    16. Loosen water pump pulley bolts.
      17.  
    17. Remove the accessory drive belt.
      18.  
    18. Remove water pump pulley.
      19.  
    19. Remove water pump.
      20.  

    To install:

    1. Install water pump. Use a new O-ring seal and tighten the bolts in a crossing pattern to 18 ft. lbs. (25 Nm).
      2.  
    2. Install water pump pulley. Tighten the bolts to 18 ft. lbs. (25 Nm).
      3.  
    3. Install the accessory drive belt.
      4.  
    4. Install belt idler bracket support.
      5.  
    5. Place A/C muffler bracket in position and tighten mounting nut.
      6.  
    6. Place power steering reservoir in position and install fasteners.
      7.  
    7. Install supercharger cooling system hose.
      8.  
    8. Install supercharger drive belt.
      9.  
    9. Install supercharger drive belt cover.
      10.  
    10. Install coolant recovery tank.
      11.  
    11. Install top radiator shield.
      12.  
    12. Connect radiator hoses.
      13.  
    13. Place coolant hose assembly in position and tighten stud.
      14.  
    14. Place wiring harness in position and tighten nut..
      15.  
    15. Fill the cooling system.
      16.  
    16. Start the engine and check for coolant leaks.
      17.  

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