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...

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...

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...

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,...

... 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...

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...

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...