Mounting water pump on engine block

Tiny
MELODY
  • MEMBER
  • 1993 MERCURY SABLE
  • 6 CYL
  • FWD
  • AUTOMATIC
  • 23,258 MILES
I'm replacing a water pump in a 1993 Mercury Sable 3.8L FI 6 cylinder. It was a bit challenging taking the old one out but it seems nearly impossible to put the new one in. I even filed the bolts down a little to see if it would go on easier but didn't want to take too much off so I can't torque it. Please don't tell me I have to lift the whole engine out. I'm puzzled and frustrated.
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Friday, December 3rd, 2010 AT 3:41 AM

4 Replies

Tiny
JACOBANDNICKOLAS
  • EXPERT
Are you able to access it if you remove the inner fender?
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Friday, December 3rd, 2010 AT 3:46 AM
Tiny
BMRFIXIT
  • EXPERT
Installation

NOTE: Lightly oil all bolt and stud threads before installation except those requiring special sealant.

CAUTION: Use care when scraping as aluminum gouges easily which may form leak paths.

Clean gasket surfaces on water pump and front cover.
Position a new gasket on water pump sealing surface using Gasket and Trim Adhesive D7AZ-19B508-B (ESE-M2G52-A and ESE-M2G52-A) or equivalent to hold gasket in place.
With pulley loosely positioned on water pump hub, align water pump to timing cover and install retaining bolts.
NOTE: Apply Pipe Sealant with Teflon D8AZ-19554-A (ESG-M4G194-A and ESR-M18P7-A) or equivalent to bolt No. 3 (as illustrated) prior to installation.

Tighten retaining bolts as follows: Numbers 3, 4, 6, 7, 8, 9 and 10 to 20-30 Nm (15-22 lb-ft) and Numbers 11, 12, 13, 14 and 15 to 8-12Nm (71-106 lb-in).
Hand tighten water pump pulley retaining bolts.
Install automatic belt tensioner assembly. Tighten the two retaining nuts and bolt to 48 Nm (35 lb-ft).
Install the generator and power steering drive belts as outlined in Section 03-05. Final tighten water pump pulley retaining bolts to 21 Nm (16 lb-ft).
Position the clamps between the alignment marks on both ends of the hose and slide hose on connections.
CAUTION: Ensure the clamps are beyond the bead and placed in the center of the clamping surface of the connection.

Any used hose clamps must be replaced with a new clamp to ensure proper sealing at the connection.

Tighten screw clamps to 2.3-3.4 Nm (20-30 lb-in).

Fill and bleed cooling system with specified quantity and type.
Connect negative battery cable.
Start engine and check for leaks.
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Friday, December 3rd, 2010 AT 3:47 AM
Tiny
JIS001
  • EXPERT
You will need to lift the engine to replace the water pump. Here are the instructions.

Water Pump

Tools Required:

Engine Support Bar D88L-6000-A
Removal

Drain cooling system.
Raise and support engine using Engine Support Bar D88L-6000-A or equivalent.
Remove lower nut on both RH engine mounts.
Raise engine.
Loosen accessory drive belt idler. Remove drive belt and water pump pulley.
Remove power steering pump mounting bracket retaining bolts. Leaving hoses connected, place pump I bracket assembly aside in a position to prevent fluid from leaking out.
If equipped with air conditioning, remove the compressor front support bracket. Leave compressor in place.
Disconnect coolant bypass hose at water pump.
Disconnect heater hose at water pump.
CAUTION:
If using a prying device to assist in water pump removal, be careful not to damage the mating surfaces.

Remove water pump retaining bolts and pump. Discard old gasket.

NOTE:
Lightly oil all bolt and stud bolt threads before installation except those specifying special sealant.

Clean gasket surfaces on water pump and front cover.
Position a new gasket on water pump sealing surface. Gasket and Trim Adhesive D7AZ- 1 9B508-B (ESR-M lip 1 7-A and ESE-M2G52-A) or equivalent is recommended to hold the gasket in position.
NOTE:
The threads of the No.1 front cover retaining stud must be coated with Pipe Sealant with Teflon D8AZ- 19554-A (ESG-M4G 194-A and ESR-M 1 8P7-A) or equivalent before installing.

Position water pump on the front cover. Install retaining bolts. Tighten retaining bolts to 20-30 N.M (15-22 lb-ft).
Connect cooling bypass hose, heater hose and radiator lower hose to water pump. Tighten clamps securely.
If equipped with air conditioning, install compressor front support bracket. Tighten retaining bolts to 41-61 N.M (30-44 lb-ft).
Position power steering pump and mounting brackets. Install the retaining bolts. Tighten to 40-62 N.M (30-45 lb-ft).
Position accessory drive belt over pump pulley and adjust drive belt tension.
CAUTION:
This engine has aluminum cylinder heads and requires a special corrosion inhibiting coolant to avoid cooling system damage.

Fill cooling system with specified coolant.
Start engine and check for coolant leaks.

Wshat you can try is removing the engine mount nuts like stated earlier in the instructions and use a floor jack with a piece of 2x4 and jack up the engine to raise the engine up. Do it from the front of the engine (passenger side) and that should give you more clearance to install the bolts. Hope that works for you and keep me posted.
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Friday, December 3rd, 2010 AT 3:51 AM
Tiny
BMRFIXIT
  • EXPERT
3.8L Engine

Removal

Drain engine coolant.
Disconnect battery ground cable.
Loosen accessory drive belt idler and remove drive belts.
Remove two nuts and one bolt attaching idler bracket to engine.
Disconnect heater hose at water pump.
Remove four pulley-to-pump hub bolts. The pulley will remain loose on hub due to insufficient clearance between inner fender and pump, restricting removal from vehicle.
Remove 11 water pump-to-engine retaining bolts.
Lift water pump and pulley out of vehicle.
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Friday, December 3rd, 2010 AT 3:52 AM

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