Wednesday, October 19, 2011

How to replace water pump on 1989 Mercury Cougar?



Replacing water pump on mercury cougar is not very easy.If you are doing this for the first time.Then its not your job.If you are a mechanic or if you own a car garage or if you have proper technical knowledge to work on car parts.Then you can definitely do it.




The procedure with complete details is mentioned below with diagrams for additional help.

3.8L Engine
WATER PUMP
See Figures 2, 3, 4 and 5
Disconnect the negative battery cable.
Properly drain the cooling system into a suitable container.
Remove the cooling fan and fan shroud, as outlined earlier in this section.
Release the belt tensioner, then remove the accessory drive belt(s).
If the vehicle is equipped with air conditioning, remove the idler pulley bracket and air conditioner drive belt.
On engines with a Thermactor®, remove the belt.
Unfasten the bolts retaining the water pump pulley to the water pump, then remove the pulley.
Remove the power steering pump pulley and remove the water pump-to-power steering pump brace.


On some supercharged models, it may be necessary to remove the charge air cooler to gain access to the power steering pump pulley.
Detach the water bypass hose at the water pump.
Disconnect the heater hose at the water pump and disconnect the lower radiator hose. On SC models, disconnect the oil cooler inlet tube and hose.
On SC vehicles, remove the Crankshaft Position (CKP) sensor upper shield.
Unfasten the bolts retaining the water pump to the engine, then remove the water pump from the vehicle.

Click image to see an enlarged view 
Fig. Fig. 2: Unfasten the retaining bolts, then ...
Click image to see an enlarged view
Fig. Fig. 3: ... remove the water pump from the vehicle

To install:
Clean any gasket material from the pump mating surfaces. On engines equipped with a water pump backing plate, remove the plate, clean the gasket surfaces, install a new gasket and plate on the water pump.
Click image to see an enlarged view 
Fig. Fig. 4: When cleaning the gasket surfaces be careful not to gouge the surfaces, which may cause leakage

Coat both sides of the new gasket with a water-resistant sealer, then position the gasket on the water pump housing.
The use of gasket adhesive is recommended.
Install the water pump, then tighten the retaining bolts, in the sequence shown in the accompanying figure, to 15-22 ft. lbs. (20-30 Nm).

FIG : Fig. 5: The water pump retaining bolts must be tightened in sequence to prevent possible coolant leakage
image

On SC vehicles, install the CKP sensor upper shield.
Connect the water bypass hose at the water pump, then tighten the clamps (and oil cooler inlet tube and hose).
Attach the heater hose at the water pump and connect the lower radiator hose and tighten the clamps.
Install the power steering pump pulley and water pump-to-power steering pump brace. If removed, install the charge air cooler.
Install the water pump pulley and tighten the retaining bolts to 15-22 ft. lbs. (20-30 Nm).
On engines with a Thermactor®, install the belt.
If the vehicle is equipped with air conditioning, install the idler pulley bracket and air conditioner drive belt.
Install the accessory drive belt(s).
Install the cooling fan and shroud, as outlined earlier in this section.
Fill the engine cooling system with the proper type and quantity of coolant. Connect the negative battery cable.
Start and run the engine and inspect for leaks. Check the coolant level, and add if necessary.




INTAKE MANIFOLD
3.8L Engine
See Figures 2 through 10
Disconnect the negative battery cable.
Remove the air cleaner assembly including the air intake duct and heat tube.
Disconnect the accelerator cable from the carburetor or throttle body, as applicable. If equipped, also disconnect the speed control cable.
Detach the transmission linkage at the carburetor or fuel charging assembly, as applicable.
Unfasten the retaining bolts from the accelerator cable bracket, then position the cables aside.
If equipped with an SC engine, remove the supercharger as follows:
Remove the cowl vent screens.
Tag and disconnect the right side spark plug wires from the ignition coil and move out of the way. Detach the fuel charging wiring connectors at the Idle Air Control (IAC) valve, Throttle Position (TP) sensor, and Intake Air Temperature (IAT) sensor.
Tag and disconnect the vacuum lines from the supercharger bypass valve actuator and fuel pressure regulator. Detach the crankcase ventilation tube.
Disconnect the EGR valve-to-exhaust manifold tubes from the EGR valve.
Remove the EGR transducer.
Remove the supercharger drive belt.
Remove the charge air cooler inlet tube and outlet tube.
Unfasten the three charge air cooler-to-intake manifold adapter retaining bolts.
Remove the three supercharger retaining bolts, then lift the supercharger and charge air cooler-to-intake manifold adapter from the vehicle as a unit. Remove and discard the gasket, then clean all mating surfaces.
FIG : Fig. 2: Removal of the throttle body/supercharger assembly
    1. image
    2. If equipped, disconnect the Thermactor air supply hose at the check valve. The valve is located at the back of the intake manifold. Disconnect and plug the fuel lines from the carburetor or fuel charging assembly, as applicable. Detach the upper radiator hose at the thermostat housing. Disconnect the coolant bypass hose at the intake manifold. Disconnect the heater tube at the intake manifold. Remove the heater hose at the rear of the heater tube. Loosen the hose clamp at the heater elbow and remove the heater tube with the hoses attached. On fuel injected engines, remove the heater tube with the fuel lines attached and position the assembly aside. Tag and disconnect the vacuum lines at the carburetor/fuel charging assembly and the intake manifold. Tag and detach all necessary electrical connectors. If equipped with A/C, remove the compressor mounting bracket. Disconnect one crankcase ventilation tube at the upper intake manifold and at the PCV valve. Remove the second crankcase ventilation tube from the left valve cover. Remove the carburetor or throttle body assembly, as applicable. If equipped with a carburetor, remove and discard the phenolic gasket. Remove the EGR valve from the upper intake manifold. Unfasten the retaining nut and remove the wiring retainer bracket located at the left front of the intake manifold and set aside with the spark plug wires. Unfasten the upper intake manifold retaining bolts and stud bolts, then remove the upper intake manifold from the vehicle. Remove and discard the gasket and thoroughly clean all mating surfaces.

    3. Click image to see an enlarged view
      Fig. Fig. 3: Unfasten the upper manifold bolts, then ...
      Click image to see an enlarged view
      Fig. Fig. 4: ... remove the upper intake manifold (and throttle body) assembly-3.8L non-SC engine shown


      Click image to see an enlarged view 
      Fig. Fig. 5: Remove the upper intake manifold gasket, then clean the mating surfaces
      Remove the fuel injectors and the fuel injection supply manifold.
      Remove the heater water outlet tube.
      Disconnect the upper radiator hose from the water hose connection.

      WARNING The intake manifold is sealed at each end with silicone sealer. To break the seal, it may be necessary to pry on the front of the intake manifold with a suitable prybar. If this is necessary, be careful not to damage the machined surfaces or engine oil and coolant leakage may occur.
    4. Unfasten the lower intake manifold retaining bolts and stud bolts. Remove the lower intake manifold. Remove and discard the gasket and end seals and thoroughly clean all mating surfaces.

      Click image to see an enlarged view 
      Fig. Fig. 6: Unfasten the lower intake manifold retaining bolts, then ...


      Click image to see an enlarged view 
      Fig. Fig. 7: ... remove the lower manifold from the vehicle


      Click image to see an enlarged view
      Fig. 8: Remove and discard the lower manifold gasket, then thoroughly clean the gasket mating surfaces

      If the lower manifold is to be disassembled, perform the following:
      Remove the water hose connection and thermostat.
      Remove the ECT sensor.
      Remove the heater elbow.
      Remove all vacuum and electrical fittings.

      To install:
      Lightly oil all retaining bolt and stud bolt threads before installation.
      If the intake manifold was disassembled, perform the following:
      Apply a coat of Pipe Sealant with Teflon® D8AZ-19554-A or equivalent to the threads of the EGR sensor, all vacuum fittings and heater elbows, if equipped.
      Install the thermostat and water hose connection gasket. Install the water hose connection and tighten the retaining bolts to 15-22 ft. lbs. (20-30 Nm).

      Before applying sealer, clean the mating surfaces with Metal Surface Cleaner F4AZ-19A536-A or equivalent.
      The SC engine uses a graph-oil type intake manifold gasket.
      Apply a dab of Gasket and Trim Adhesive D7AZ-19B508-B or equivalent to each cylinder head mating surface. Press new intake manifold gasket into place, using location pins as necessary to aid in alignment.

      When using silicone rubber sealer, assembly must occur within 15 minutes after application or the sealer may start to set.
      Apply a 3 / 4 in (3-4mm) bead of Silicone Rubber D6AZ-19562-BA or equivalent, at each corner where the cylinder head joins the block. Install new front and rear intake manifold seals.
      Carefully lower the lower intake manifold into position on the block and cylinder heads. Install the retainers in the original locations. Tighten in sequence to the following specifications, in two steps:

      Step 1: 13 ft. lbs. (18 Nm) Step 23: 16 ft. lbs. (22 Nm)

      FIG : Fig. 9: Lower intake manifold tightening sequence-3.8L non-SC engine
    5. image
    6. FIG : Fig. 10: Lower intake manifold tightening sequence-3.8L SC engine
      image
    7. Install the heater water outlet tube so that the mounting bracket sits over the lower intake manifold stud bolt. Tighten the nut on the stud bolt to 15-22 ft. lbs. (20-30 Nm). Install and tighten the retaining bolt on the water pump to 6-8 ft. lbs. (8-11 Nm). Install the fuel injectors and fuel supply manifold. Connect the upper radiator hose to the water hose connection and tighten the clamp securely. For non SC engines, position a new upper intake manifold upper gasket and upper intake manifold on top of the lower intake manifold. Install the bolts and stud bolts in their original locations, then tighten in the sequence shown to the following specifications: Step 1: 8 ft. lbs. (15 Nm) Step 2: 15 ft. lbs. (20 Nm) Step 3: 24 ft. lbs. (32 Nm) FIG : Fig. 11: Non-SC engine upper intake manifold tightening sequence
      1. image
      2. For SC engines, install the supercharger as follows: Position a new gasket on the lower intake manifold. Install the supercharger and charge air cooler to the intake manifold as a unit. Tighten the two 8mm bolts to 15-22 ft. lbs. (20-30 Nm). Tighten the 12mm bolt to 52-70 ft. lbs. (70-95 Nm). Install the three charge air cooler-to-intake manifold adapter retaining bolts. Tighten to 20-28 ft. lbs. (26-38 Nm). Install the charge air cooler inlet tube and outlet tube as outlined. Attach the EGR valve-to-exhaust manifold tube to the EGR valve. Install the EGR transducer. Install the accelerator cable bracket, then connect the accelerator cable. Tighten the bolt to 10-15 ft. lbs. (14-20 Nm). Connect the vacuum lines to the supercharger bypass valve actuator and fuel pressure regulator. Attach the right side spark plug wires, as tagged during removal. Connect the fuel charging wiring connectors at the Idle Air Control (IAC) valve, Throttle Position (TP) sensor, and Intake Air Temperature (IAT) sensor. Install the cowl vent screens. Install the throttle body. Tighten the retaining nuts in a criss-cross pattern to 15-22 ft. lbs. (20-30 Nm). Connect the rear crankcase ventilation tube at the positive crankcase ventilation valve on the upper intake manifold. For non-SC engines, if equipped, install the A/C compressor mounting bracket. Tighten the retaining nut to 15-22 ft. lbs. (20-30 Nm). If equipped, connect the speed control actuator cable. Attach the throttle valve control actuating cable at the upper intake manifold. For SC engines, install the supercharger and charge air cooler tubes. Connect the negative battery cable. Properly fill the engine cooling system.
    8. ----------

This procedure will help.



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