Lincoln Aviator, Ford Explorer, Exp Sport, Exp Sport-Trac, Mercury Mountaineer 2000-2005

Removal & Installation

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4.0L Engine



VIN E Engine


Click image to see an enlarged view

Fig. Water pump installation-4.0L engine

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    WARNING
    Use care when scraping the water pump-to-engine block mating surfaces. Gouges in the aluminum could form leak paths.



    Fan shroud
     
    Accessory drive belt
     
    Idler pulley
     
    Water bypass hose
     
    Heater hose
     
    Lower radiator hose
     
    Water pump pulley
     
    Water pump
     

  6.  
  7. Clean all the sealing surfaces.
  8.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Observe the following tightening torques:

    Water pump bolts 89 inch lbs. (10 Nm).
     
    Pulley bolts 18 ft. lbs. (25 Nm).
     

  4.  

  1. Before servicing the vehicle, refer to the -Precautions- section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    WARNING
    Use care when scraping the water pump-to-engine block mating surfaces. Gouges in the aluminum could form leak paths.



    Fan shroud and cooling fan
     
    Accessory drive belt
     
    Water pump pulley
     
    Coolant by-pass hose
     
    Lower radiator hose
     
    Water pump
     

  6.  
  7. Clean all the sealing surfaces.

    Click image to see an enlarged view

    Fig. Typical water pump installation-4.0L engine

  8.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Observe the following tightening specifications:

    Water pump bolts: 89 inch lbs. (10 Nm)
     
    Pulley bolts: 18 ft. lbs. (25 Nm)
     

  4.  

  1. Drain the cooling system.
  2.  
  3. Remove or disconnect the following:

    Accessory drive belt
     
    Cooling fan and shroud
     
    Accessory drive belt idler pulley
     
    Water by-pass hose (slide clamp back from water pump connection)
     
    Lower radiator hose
     
    Water pump pulley
     
    Water pump
     

  4.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Observe the following tightening specifications:

    Water pump mounting bolts: 89 inch lbs. (10 Nm)
     
    Water pump pulley bolts: 18 ft. lbs. (25 Nm)
     
    Idler pulley bolt: 33 ft. lbs. (45 Nm)
     

  4.  

4.6L (VIN W, H, 8) Engine



  1. Before servicing the vehicle, refer to the -Precautions- section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Engine cooling fan
     
    Upper fan shroud
     
    Water pump pulley bolts (loosen only)
     
    Accessory drive belt
     
    Water pump pulley
     
    Water pump
     

  6.  
  7. Discard the O-ring seal.

    Click image to see an enlarged view

    Fig. Water pump installation-4.6L (VIN 8, H) engine

  8.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Install a new O-ring seal and lubricate with engine coolant.
  4.  
  5. Observe the following tightening specifications:

    Water pump mounting bolts: 18 ft. lbs. (25 Nm).
     
    Water pump pulley bolts: 18 ft. lbs. (25 Nm).
     

  6.  

4.6L Engine





Click image to see an enlarged view

Fig. Water pump installation-4.6L SOHC and DOHC engines

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Engine cooling fan
     
    Drive belt
     
    Water pump pulley
     
    Water pump
     

  6.  
  7. Discard the O-ring seal.
  8.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Install a new O-ring seal and lubricate with engine coolant.
  4.  
  5. Observe the following tightening torques:

    Pump bolts 18 ft. lbs. (25 Nm).
     
    Pulley bolts 18 ft. lbs. (25 Nm).
     

  6.  

5.0L Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fan shroud
     
    Drive belt
     
    Water bypass hose
     
    Heater hose from the water pump
     
    Engine control sensor wiring and move it aside
     
    Water pump pulley
     
    Water pump from the engine front cover
     
    Water pump inlet hose
     
    Water pump
     

  6.  

To install:

  1. Clean the mounting surfaces of the pump and front cover thoroughly. Remove all traces of gasket material.
  2.  
  3. Install or connect the following:

    Apply adhesive gasket sealer to both sides of a new gasket and place the gasket on the pump.
     
    Inlet hose to the water pump. Torque the clamps to 11 ft. lbs. (15 Nm).
     
    Water pump. Torque the bolts to 20 ft. lbs. (28 Nm).
     
    Water pump pulley. Torque the bolts to 20 ft. lbs. (28 Nm).
     
    Engine control sensor wiring
     
    Heater hose
     
    Water bypass tube. Torque the clamps to 11 ft. lbs. (15 Nm).
     
    Dive belt
     
    Fan shroud
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the vehicle and check for leaks, repair if necessary.
  8.  

 
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