Mercury cougar water pump replacement

Usually you have to borrow or rent a pulley puller to remove it and re-install.

Hi, Please follow below steps :

-. Jack up front wheel and remove the tires
-. Remove the Motor Mount next to the Power Steering Pump and timing belt cover

-. Loosen the Alternator/Water Pump belt.
-. Loosen the Power Steering/AC/Tensioner belt by loosening the Tensioner Bolt first.

-. Remove the power steering pump bracket. Leave the pump attached to the bracket.
-. Remove the Water Pump Pulley.

-. Now it's time to remove the Crank Pulley.

-. Remove the Timing Cover bolts.

-. Remove and replace the crankshaft sensor

If you open the hood and look around the frame of the engine compartment, or on the under side of the hood, there should be a diagram available that shows the way the belts are run on your cougar. It will show you the alternator, water pump, power steering pump, crank pulley, tensioner, A/C and any extra pulleys.

Usually it is located somewhere above the crank pulley a bit to the left or right.

Hopfully this will be ALL you need Besides Pulley REMOVAL TOOL It can be Rented @ AutoZONE

REMOVAL

1. Remove drive belt.
2. Raise vehicle on hoist. WARNING: TURN AIR SUSPENSION SWITCH (LOCATED IN LUGGAGE COMPARTMENT) OFF TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY.
3. Remove power steering pressure hose bracket.
4. Disconnect electrical connector at power steering control valve actuator.
   1. Install Steering Pump Pulley Remover T69L-10300-B on the pulley hub. CAUTION: Do not apply in-and-out pressure on the power steering pump shaft. Pressure will damage the internal thrust areas.
   2. Hold the small hex-head and rotate the tool nut counterclockwise to remove the power steering pump pulley.
   3. Disconnect power steering pressure hose at power steering pump and drain fluid into a container.
   4. Disconnect power steering return hose at power steering pump and drain fluid into a container.
   5. Remove four retaining bolts and power steering pump and power steering pump pulley assembly.
   6. Remove power steering pressure switch from pump.
   INSTALLATION
   
   1. Position the power steering pump on the mounting bosses of engine block and install the bolts at the side of the power steering pump. Tighten to 20-30 Nm (15-22 ft. lbs.).
   2. Connect the power steering reservoir pump hose to the power steering pump and reposition the hose clamp to power steering pump inlet fitting.
   3. Replace power steering pressure hose O-ring.
   4. Install the power steering pressure hose to the power steering pump fitting. Tighten the tube nut with a tube nut wrench rather than with an open-end wrench. Tighten to 34-46 Nm (26-33 ft. lbs.). NOTE: Swivel or end play of the power steering pressure hose end is normal and does not indicate a loose fitting.
   5. Place the power steering pump pulley on the power steering pump shaft and install Power Steering Pump Pulley Replacer T91P-3A733-A. The small diameter threads on the tool should be engaged in the power steering pump shaft. CAUTION: Do not apply in and out pressure on the shaft. Pressure will damage the internal rotating group.
   6. Hold the small hex-head and rotate the tool nut clockwise to install the power steering pump pulley on the shaft. CAUTION: Do not apply in and out pressure on the shaft. Pressure will damage the internal rotating group. NOTE: The power steering pump pulley face must be flush within 0.25 mm (0.010 inch) of the end of the pump shaft.
   7. Remove the Power Steering Pump Pulley Replacer T91P-3A733-A.
   8. Remove the shipping tube nut from power steering pump housing prior to installation.
   9. Connect electrical connector to power steering control valve actuator.
   1. Install power steering pressure hose bracket.
   1. Lower the vehicle.
   2. If equipped, turn the air suspension ON.
   3. Install drive belt on the power steering pump pulley.
   4. Fill the power steering pump reservoir with Power Steering Fluid Motorcraft MERCON(r) ATF.

Power steering pump special tools


Power Steering Pump Removal & Installation Power Steering Pump (2V) To Remove:

1. Before servicing the vehicle refer to the precautions at the beginning of this section.
2. Disconnect the battery ground cable.
3. Remove the accessory drive belt.
4. Remove the alternator.
5. Drain and remove the radiator coolant recovery reservoir.
6. Position a drain pan under the power steering pump underneath the vehicle. Disconnect the hydraulic pressure and return lines and allow to drain.
7. Remove the idler pulley from the power steering pump support.
8. Remove the belt tensioner.
9. Remove the bracket mounting bolt located under the belt tensioner mounting.
10. Remove two retaining nuts from the bracket mounting studs. Remove both mounting studs, and pull off the power steering pump support with the pump attached.
11. Clamp the pump support bracket in a suitable vise.
12. Remove the power steering pump pulley from the pump shaft using Pump Pulley Remover T69L-10300-B, or equivalent. Remove the three bolts retaining the power steering pump to the power steering pump support and remove the power steering pump.

To Install:
NOTE: The pulley must be installed within 0.010 in (0.25 mm) flush with the power steering pump shaft.

1. Install the power steering pump to the power steering pump support. Tighten the mounting bolts to 18 ft-lb. (25 Nm).
2. Install the power steering pump pulley using Steering Pump Pulley Replacer T65P-3A733-C, or equivalent; the pulley face must be flush within 0.010 inch (0.25mm) of the pump shaft.
3. Install the power steering pump/pump support and torque nuts/bolt to 24 ft. lbs. (33 Nm).
4. Install the bracket mounting bolt located under the belt tensioner mounting.
5. Install the belt tensioner.
6. Install the idler pulley to the power steering pump support.
7. Connect the hydraulic pressure and return lines.
8. Install the radiator coolant recovery reservoir.
9. Install the alternator.
10. Install the accessory drive belt.
11. Fill the power steering reservoir with power steering fluid.
12. Connect the battery ground cable.
13. Run the engine and check for leaks and proper operation. Bleed the power steering system if needed.

I don't have chrysler producs. I'll post 3.8L V6 Ford Windstar for reference. You'll get some idea.



Removal
WARNING: USE CAUTION WHEN REMOVING OR INSTALLING DRIVE BELT TO MAKE SURE THAT TOOL DOES NOT SLIP.

1. Using a 15mm socket or wrench on bolt attaching drive belt tensioner pulley. Rotate drive belt tensioner (6B209) clockwise to remove drive belt from pulleys.
   
   3.8L Engine
   
   

Item Part Number Description 1 10300 Generator 2 3A674 Power Steering Pump 3 19703 A/C Compressor 4 6B217 Drive Belt Tensioner Pulley 5 6312 Crankshaft Pulley 6 8501 Water Pump 7 6B209 Drive Belt Tensioner 8 8620 Drive Belt
Installation

1. Install drive belt over all pulleys (except drive belt tensioner ).

1. Rotate drive belt tensioner as described under Removal and install drive belt over drive belt tensioner pulley. Ensure that all V-grooves make proper contact with pulleys

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Another example
Pulley, Power Steering Pump CII
SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Steering Pump Pulley Remover T69L-10300-B Steering Pump Pulley Replacer T65P-3A733-C
Removal

1. Drain as much fluid as possible from the power steering pump (3A674) through the power steering oil reservoir (3A697) neck.

1. Install Steering Pump Pulley Remover T69L-10300-B on the power steering pump pulley (3A733) , and place the tool and power steering pump in a vise by gripping the small hex-head of the tool.

1. Hold the power steering pump , and rotate the tool nut counterclockwise to remove the power steering pump pulley . Do not apply in and out pressure on the power steering pump shaft. Pressure will damage the internal thrust areas.
   
   

Installation
CAUTION: Do not apply in and out pressure on the shaft. Pressure will damage the internal thrust areas.

1. Place the power steering pump pulley on the power steering pump shaft, and install Steering Pump Pulley Replacer T65P-3A733-C. The small diameter threads on the tool should be fully engaged in the power steering pump shaft.

1. Hold the power steering pump , and rotate the tool nut clockwise to install the power steering pump pulley on the shaft. The power steering pump pulley face must be flush within 0.25mm (0.010 inch) of the end of the power steering pump shaft.

1. Remove the tool.

1. Fill the power steering oil reservoir to the COLD FILL line.

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Steering Pump, Power Removal

1. Disconnect battery ground cable (14301) .

1. Remove accessory drive belt (8620) .

1. Raise vehicle on hoist. Refer to Section 00-02 .

1. Remove right front wheel (1007) and tire assembly.

1. Remove power steering pump pulley (3A733) .

1. Position drain pan. Remove power steering pressure hose (3A719) and power steering return hose (3A713) from power steering pump (3A674) .

1. Remove four power steering pump retaining bolts (three in front, one in rear) and remove power steering pump .

Installation

1. Position power steering pump and install retaining bolts. Tighten retaining bolts to 41-54 Nm (30-40 lb-ft).

1. Install power steering pressure hose and power steering return hose to power steering pump . Remove drain pan.

1. Press on power steering pump pulley as outlined in this section.

1. Install right front wheel and tire assembly. Tighten lug nuts (1012) to 115-142 Nm (85-105 lb-ft).

1. Lower vehicle.

1. Install drive belt to power steering pump pulley .

1. Connect battery ground cable .

1. Fill power steering oil reservoir (3A697) to proper level. Refer to Section 11-00 .
   
   Power Steering Pump and Bracket, 3.8L
   
   

Item Part Number Description 1 N607528-S2 Screw, M6-1 x 16 2 8509 Water Pump Pulley 3 W804804-S2 Screw, M8-1.25 x 35 4 N806214-S2 Bolt, M12 5 W606691-S36B Screw, M8-1.25 x 35 6 10B315 Generator Brace 7 N621939-S36B Nut, M8-1.0 8 10300 Generator 9 6B212 Accessory Drive Belt Tensioner Bracket 10 6049 Cylinder Head 11 19D624 Air Conditioning Compressor Bracket 12 W606563-S2 Bolt, M10-1.5 x 55 13 19703 A/C Compressor 14 N807273-S100 Bolt, M8-1.25 x 121.5 15 3C510 Power Steering Hose Bracket 16 3A674 Power Steering Pump 17 3C511 Power Steering Pump Support 18 W807239-S8 Bolt, M10-1.5 x 36.5 19 2888 A/C Compressor Brace 20 W806342-S2 Bolt, M8-1.25 x 23 21 W606571-S411 Bolt, M10-1.5 x 113.5 22 6C348 Idler Assembly 23 3A733 Power Steering Pump Pulley 24 N805137-S56 Bolt, M10-1.5 x 157 25 N621939-S2 Nut, M8-10 26 N807241-S36B Bolt, M10-1.5 x 132 27 6B209 Drive Belt Tensioner A — Tighten to 8-11 Nm (71-101 Lb-In) B — Tighten to 20-25 Nm (15-18 Lb-Ft) C — Tighten to 70-95 Nm (52-70 Lb-Ft) D — Tighten to 40-55 Nm (30-40 Lb-Ft) E — Press Flush with End of Power Steering Pump Shaft

REMOVAL

1. Remove ground terminal from battery.
2. Remove pulley belt cover bracket.

1. Loosen lock bolt and slider bolt and remove power steering pump drive V-belt.
2. Disconnect connector from power steering pump switch.

1. Disconnect pipe C and suction hose from oil pump. CAUTION:

• Do not allow fluid from the hose end to come into contact with pulley belt.
• To prevent foreign matter from entering the hose and pipe, cover the open ends of them with a clean cloth.

1. Remove bolts which install power steering pump bracket.

1. Place oil pump bracket in a vise, remove two bolts from the front side of oil pump. CAUTION: Do not place oil pump bracket directly in the vise; use soft pads and hold oil pump lightly to protect the pump.

1. Remove socket from oil pump.
2. Remove bolt from the rear side of oil pump.

If the pulley is pressed on you need a special tool to remove it and to press it back on. Check with your local parts house to see if they have the tool.

From the sounds of it you have the 3.8L V6, to get that bracket off you will need to remove the power steering pulley, to do this you will need a power steering pulley remover and installer, the only other way is to cut the bracket which is not a good idea.

yes you do. auto zone loan a tool pulley tool. pull off press on. good luck