Ford Contour/Mystique/Cougar 1995-1999 Repair Guide

Water Pump

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REMOVAL & INSTALLATION



2.0L Engine -1995-97


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Fig. Fig. 1: Water Pump components

Disconnect negative battery cable.Raise vehicle on hoist.Remove right front wheel assembly.Remove crankshaft pulley shield retaining screws and shield.Remove drive belt.Using Strap Wrench D85L-6000-A to prevent engine from rotating, remove crankshaft pulley bolt and pulley.Remove lower timing belt cover bolts.Remove front splash shield retainers and shield.Partially lower vehicle.Drain the engine cooling system.Tighten drain petcock.Lower vehicle.Remove two engine intake air resonator nuts and bolt, loosen the hose clamp at inlet tube, disconnect sensor, and remove intake air resonator.Loosen coolant reservoir hose clamps. Disconnect hoses and position aside.Remove two screws retaining coolant reservoir to the inner fender and one screw retaining hose locator to inner fender. Remove reservoir.
CAUTION
Position a block of wood between oil pan and floor jack. Position a floor jack under oil pan and slightly raise it to release pressure from front insulator.


NOTE
Make a reference mark to aid during installation.

Remove six front engine support insulator bracket nuts and bracket.Remove three front insulator bolts and insulator.Remove power steering reservoir line nut and two bolts retaining the pump line at engine lifting eye and steering pump bracket.Remove oil level indicator, three exhaust heat shield bolts, and air conditioning hose bracket nut. Position bracket aside. Remove heat shield stud and shield.Remove four power steering pump bolts. Position and secure pump assembly aside.Disconnect the lower radiator hose at water pump and position it aside.

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Fig. Fig. 2: Remove the lower radiator hose from the back of the water pump

Remove the lower radiator hose from the back of the water pumpDisconnect ignition wires from spark plugs and position them aside. Remove 8 mm upper timing belt cover bolts and upper timing belt cover. Remove 10 mm valve cover bolts and valve cover. Discard gasket.Remove idler pulley bolt and pulley.Remove water pump pulley bolts and pulley.Remove center timing belt cover bolts, center cover, and lower cover.Using Camshaft Alignment Tool T94P-6256-CH and Camshaft Sprocket Holding Tool T74P-6256-B, align the camshafts by installing tool into the slots at the rear of camshafts.
NOTE
If the timing belt is to be reused, mark the direction of the belt to aid during installation.



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Fig. Fig. 3: The water pump is retained by four bolts

Remove four water pump bolts and water pump.

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Fig. Fig. 4: Carefully remove the water pump from the engine block

Clean the water pump-to-engine mounting surface.

To install:

Position water pump and install bolts. Tighten bolts to 15-20 Nm (12-15 ft. lbs.).Loosely install timing belt tensioner, bolt, and belt. Adjust belt tension. Tighten bolt to 35-40 Nm (26-30 ft. lbs.).Position lower timing belt cover. Install center cover and bolts. Tighten bolts to 6-8 Nm (53-71 inch lbs.).Position water pump pulley and securely install bolts.Install idler pulley assembly and tighten bolts to 48 Nm (35 ft. lbs.).Remove camshaft alignment tool.Using a new gasket, position valve cover and install bolts. Initially tighten all bolts to 2 Nm (18 inch lbs.) and then tighten them to 6-8 Nm (53-71 inch lbs.). Connect spark plug wires.Position upper timing belt cover and install bolts. Tighten bolts to 3-5 Nm (27-44 inch lbs.).Connect lower radiator hose to the water pump.Position power steering pump assembly to bracket and install four power steering pump bolts. Tighten bolts to 25 Nm (18 ft. lbs.).Position front insulator and power steering hose bracket. Install three bolts and tighten them to 70-95 Nm (52-70 ft. lbs.).Position front engine support bracket and install six nuts. Tighten nuts to 70-95 Nm (52-70 ft. lbs.).Remove the floor jack.Position coolant reservoir. Securely install two reservoir screws and one coolant hose locator screw to inner fender.Connect coolant reservoir hoses.Position exhaust heat shield, coolant tube, and hose retainers. Install three heat shield bolts and one stud. Tighten retainers to 8-11 Nm (71-97 inch lbs.). Position A/C hose bracket to stud, securely install nut and install oil level indicator.Install power steering reservoir line nut and two bolts retaining pump line at engine lifting eye and steering pump bracket. Tighten retainers to 6 Nm (53 inch lbs.).Position engine intake air resonator. Securely install one bolt and two nuts. Connect the sensor and securely tighten hose clamp to the inlet tube.Raise the vehicle.Install lower timing belt cover bolts and tighten to 6-8 Nm (53-71 inch lbs.).Using Strap Wrench D85L-6000-A to prevent the engine from rotating, install crankshaft pulley and bolt. Tighten bolt to 110-120 Nm (81-89 ft. lbs.).Install drive belt.Position crankshaft pulley shield and securely install screws.Position front splash shield and securely install screws.Install right front wheel assembly. Tighten wheel nuts to 85 Nm (62 ft. lbs.).Lower vehicle.Connect battery ground cableFill engine cooling system, start engine, and check for coolant leaks.2.0L Engine -1998-99

Save all security and radio codes.

Disconnect the battery ground cable.Drain the cooling system.Remove the wheel.Remove the bolts and remove the lower right side splash shield.

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Fig. Fig. 1: Remove the bolts and remove the lower right side splash shield

Lower the vehicle.Loosen the water pump pulley bolts.

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Fig. Fig. 2: Loosen the water pump pulley bolts

Remove the accessory drive belt.Using the special tool, remove the crankshaft pulley.

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Fig. Fig. 3: Using the special tool, remove the crankshaft pulley

Remove the bolts and remove the pulley.

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Fig. Fig. 4: Remove the bolts and remove the pulley.

Remove the water pump bolts and the water pump.

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Fig. Fig. 5: Remove the water pump bolts and the water pump.

To install:Install the water pump and bolts. Tighten bolts to 13 ft. lbs. (18 Nm)Install the water pump pulley and install the pulley bolts hand tight.Using the special tool, install the crankshaft pulley.Install the accessory drive belt.Tighten the water pump pulley bolts to 9 ft. lbs. (12 Nm)Install the splash shield.Install the road wheel.

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Fig. Fig. 6: Install the road wheel..

To install:Refill the cooling system.
 
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