2001 Water Pump Replacement

1. Raise vehicle on a hoist. Remove right inner splash shield.
2. Remove accessory drive belts.
3. Drain the cooling system.
4. Remove power steering pump attaching bolts and set pump and assembly aside. Power steering lines do not need to be disconnected.
5. Remove upper and lower torque isolator struts.
6. Support the engine from bottom and remove right engine mount attaching bolt.
7. Remove right engine mount bracket.
8. Remove the timing belt.
9. Remove the timing belt tensioner.
10. Remove camshaft sprocket and rear timing belt cover. 11. Remove water pump attaching screws to engine and remove pump.

Hi there,

In removing the water pump, these tips would help you carry out the task:

• Disconnect the car's negative battery cable.
• Drain the engine coolant by opening the drain fitting at the bottom of the radiator with pliers and letting the coolant drain into a large container. Move the container to the drain plugs at the engine block and drain the rest of the coolant from there.
• Remove the drive belts by loosening their tensioner lock nuts and adjuster bolts with a wrench and slipping the belts off the pulleys.
• Remove the drive belt idler pulley bracket and the right side engine mount with its brackets--support the engine from above with a hoist or engine support fixture, remove the upper mount bracket and through-bolt with the wrench, raise the engine higher and remove the lower bracket and mount.
• Remove the timing chain tensioner cover and the water pump cover from the timing chain cover.
• Press the timing chain's piston inward. Insert an appropriate size pin into the tensioner hole to lock it in place. Rotate the crankshaft 20 degrees counterclockwise with a breaker bar and socket at the pulley to loosen the water pump sprocket chain.
• Remove the pump's two mounting bolts with a wrench. insert two M8 bolts that are three to four inches long into the bolt holes and tighten them evenly until they force the pump out of the engine.
• Clean off any corrosion and sealant using a rag with acetone or lacquer thinner. Clean and remove all traces of gasket material from the engine surface.

For the installation:

• Install new O-rings onto the replacement pump and apply a light coat of grease to the rings.
• Attach the pump to the engine and tighten the bolts by hand first, using a small amount of RTV sealant on the bolt threads. Tighten the bolts in quarter-turn increments to between 61 and 86 foot-pounds.
• Rotate the crankshaft 20 degrees clockwise with the breaker bar and socket to tighten the timing chain around the water pump sprocket.
• Remove the pin from the timing chain tensioner. Clean off the water pump cover and tensioner cover, apply RTV sealant ot them and install them back on the timing chain cover.
• Reinstall the right side engine mount with its bolts and brackets and then lower the engine off the hoist. Reinstall the drive belt idler pulley bracket.
• Reinstall the drive belts--check the owner's manual for the routing path--and tighten them with the wrench on the bolts/nuts.
• Refill the engine coolant at the radiator filler neck, using a fresh mixture of water and antifreeze if the old coolant is contaminated.
• Reconnect the battery cable.

Glad to be of help...

Assuming this is a 460 Ford Big Block:

REMOVAL

-Drain cooling system.
-Remove drive belts.
-Remove bolts attaching fan shroud to radiator.
-Remove fan blade from fan clutch and remove fan shroud.
-Remove fan clutch and water pump pulley from water pump.
-Remove four bolts and one nut attaching A/C compressor mounting bracket to cylinder head and water pump. Do not remove A/C compressor or power steering pump from A/C compressor mounting bracket.
-Pull A/C compressor mounting bracket forward to remove from stud on water pump.
-Remove bolt attaching generator adjusting arm to water pump. Remove four bolts attaching generator mounting bracket to cylinder head, cylinder block and water pump.
-Remove remaining water pump attaching bolts and remove water pump from engine front cover.
-Remove water pump cover from water pump. Discard water pump housing gasket and water pump cover gasket.
INSTALLATION
-Remove any gasket material from water pump cylinder front cover and separator plate mating surfaces.
-Position new water pump housing gasket and water pump cover gasket coated on both sides with Perfect Seal Sealing Compound B5A-19554-A or equivalent water-resistant sealer meeting Ford specification ESE-M4G115-A.
-Position water pump and water pump cover onto engine front cover. Install bolts and tighten to16-24 Nm (12-18 ft. lbs.).
-Install generator mounting bracket to cylinder head, cylinder block and water pump with four attaching bolts. Install generator adjusting arm to water pump with one attaching bolt. Tighten 7/16-inch bolts to 54-71 Nm (40-53 ft. lbs.) and 3/8-inch bolts to 41-54 Nm (30-40 ft. lbs.).
-Position A/C compressor mounting bracket over water pump stud and secure to cylinder head with four bolts tightened to 54-71 Nm (40-53 ft. lbs.) and secure nut to water pump to 41-54 Nm (30-40 ft. lbs.).
-Install water pump pulley and fan clutch to water pump hub with four bolts. Install fan blade to fan clutch with four bolts. Tighten water pump pulley, fan clutch hub bolts, and fan-to-fan clutch hub bolts to 16-24 Nm (12-18 ft. lbs.). Install fan shroud.
-Install drive belts.
-Fill and bleed the cooling system.
-Start the engine and check for leaks

Water Pump REMOVAL & INSTALLATION 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. 1987-95 Vehicles EXCEPT 1995 VIN 1 ENGINE

1. Disconnect the negative battery cable.
2. Drain cooling system into a suitable container.
3. Remove the serpentine drive belt, as outlined in Section 1 of this manual. NOTE: On some engines, removing the alternator provides better clearance for removing the water pump. For alternator removal and installation procedures, please refer to Section 2 of this manual. Fig. 1: After removing the alternator, remove the brace
   
   
4. Unfasten the water pump pulley bolts, (long bolt removed through access hole provided in the body side rail), then remove the pulley. Fig. 2: Pull the water pump pulley from the pump
   
   
5. Disconnect the radiator and heater hoses from water pump. Fig. 3: Use a screwdriver to loosen the hose clamp screws, then disconnect the hoses from the water pump
   
   
6. For 1992-95 vehicles, remove the torque axis mount, as follows:
   1. Use a suitable engine support fixture and lifting bracket to raise the engine slightly to take the weight off of the engine mounts.
   2. Remove the through-bolt from the torque axis (front) engine mount.
   3. Lift the engine with the support fixture until the power steering reservoir touches the strut tower cross brace.
   4. Loosen the bottom two bolts on the torque axis (front) engine mount.
   5. Remove the A/C line clip and top two bolts on the torque axis engine mount, then remove the mount.
   6. Remove the 2 bolts and nut attaching the engine torque axis mount bracket assembly to the front of the engine. NOTE: On some engines, when you remove the 13mm bolts, coolant will flow from the bolt holes, so make sure to position a drain pan under the pump before unfastening the bolts.
      
7. Remove the water pump attaching bolts, then remove the water pump from the vehicle. Remove and discard the gasket. Thoroughly clean the gasket mating surfaces. Fig. 4: Unfasten the water pump mounting bolts (see arrows for locations of top bolts) . . .
   Fig. 5: . . . then remove the water pump from the engine
   Fig. 6: Use a gasket scraper to carefully clean the water pump's mating surface
   Fig. 7: You can also use Scotchbrite® or equivalent non-abrasive scouring pad to clean the water pump gasket mating surface
   Fig. 8: When using a scraper to clean the gasket mating surfaces, be careful not to gouge the engine and cause leaks
   Fig. 9: Exploded view of the water pump mounting - 1994 vehicle shown, others similar
   To install:
   
8. Apply a suitable sealant to the bolt threads. Fig. 10: Coat the bolt threads with a suitable sealing compound
   
   
9. Position a new gasket, then install the water pump to the engine and tighten the retaining bolts, as follows: Fig. 11: Place a new gasket on the water pump mounting surface
   
   1. For 1987-94 vehicles, tighten the long bolts to 29 ft. lbs. (39 Nm) and the short bolts to 97 inch lbs. (11 Nm).
   2. For 1995 vehicles, tighten the water pump-to-block bolts to 22 ft. lbs. (30 Nm) and the water pump-to-front cover bolts to 11 ft. lbs. (15 Nm), plus an additional 80°rotation.
10. For 1992-95 vehicles, install the torque axis mount, as follows:
    1. Attach the torque axis engine mount bracket assembly to the front of the engine using the 2 bolts and nut. Fig. 12: Install the torque axis engine mount bracket and secure with the 2 bolts and nut
       
       
    2. Replace the 2 upper bolts previously removed from the torque axis engine mount, and attach the mount and plastic clip for the A/C lines.
    3. Tighten the 2 lower bolts that were previously loosened on the torque axis engine mount. Fig. 13: Exploded view of the torque axis engine mount and tightening specifications
       
       
    4. Adjust the engine height to align the torque mount with the torque axis mount bracket.
    5. Insert the through-bolt, attach the retaining nut and tighten to the specifications shown in the accompanying figure. Remove the engine support and lifting fixture. Fig. 14: Insert the torque axis mount bracket through-bolt
       
    
    
11. Install the water pump pulley and secure with the retaining bolts.
12. Connect the radiator and heater hoses to the water pump.
13. Install the serpentine drive belt.
14. Connect the negative battery cable.
15. Fill cooling system and check for leaks. Start the engine and allow to come to normal operating temperature. Check for leaks and top-off the coolant.

Hope this helps you!

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions section.
   NOTE After all components are installed on the engine, a DRB® scan tool is necessary to perform the camshaft and crankshaft timing relearn procedure.
   
   
2. Drain the cooling system.
   
3. Remove or disconnect the following:
   
   • Negative battery cable
     
   • Right inner splash shield
     
   • Accessory drive belts
     
   • Power steering pump and support the engine from the bottom with a jack
     
   • Upper and lower torque isolator struts
     
   • Right engine mount
     
   • Power steering pump bracket bolts, move the pump/bracket assembly aside
     
   NOTE It is not necessary to disconnect the power steering lines.
   
   
   • Right engine mount bracket
     
   • Timing belt and timing belt tensioner
     
   • Camshaft sprocket(s)
     
   • Inner (rear) timing belt cover
     
   • Water pump and discard the O-ring
     
4. Clean all mating surfaces of any residual gasket material.
   

To install:




Water pump mounting—2002 Neon shown, other years similar



Be sure the O-ring is seated in the groove before installing the new pump

1. Install a new O-ring in the water pump groove.
   NOTE Hold the O-ring in place with a few small dabs of silicone sealant.
   
   WARNING Before proceeding, be sure the O-ring gasket is properly seated in the water pump groove before tightening the screws. An improperly installed O-ring could cause a coolant leak.
   
   
2. Install or connect the following:
   
   • Water pump, torque the bolt to 105 inch lbs. (12 Nm). Use a pressure tester to pressurize the cooling system to 15 psi (103 kPa) and check the water pump shaft seal and O-ring for leaks.
     
   NOTE Rotate the pump by hand to check for freedom of movement.
   
   
   • Inner (rear) timing belt cover
     
   • Camshaft sprocket
     
   • Timing belt tensioner and timing belt
     
   • Right engine mount bracket and engine mount
     
   • Power steering pump
     
   • Upper and lower torque isolator struts
     
   • Accessory drive belts
     
   • Negative battery cable
     
3. Refill the cooling system.
   
4. Use a DRB® scan tool to perform the camshaft and crankshaft timing relearn procedure, as follows:
   
   • Connect the scan tool to the DLC, located under the instrument panel near the steering column.
     
   • Turn the ignition switch ON, and access the “miscellaneous” screen.
     
   • Select the “re-learn cam/crank” option, then follow the instructions on the scan tool screen.
     

go here and see the files section for porcedures. Change timing belt at same time. You are already there. This is a one day job.

http://groups.yahoo.com/group/villagerquest/


SECTION 303-03: Engine Cooling 2001 Villager Workshop Manual
REMOVAL AND INSTALLATION Water Pump Removal

1. Drain the engine cooling system. Refer to Cooling System Draining, Filling And Bleeding .

1. Remove the crankshaft pulley. Refer to Section 303-01 .

1. Remove the water pump pulley.
   1. Remove the bolts.
   1. Remove the water pump pulley.

1. Remove the six lower timing belt cover bolts.

1. Lower the vehicle.

1. Remove the upper radiator hose.
   1. Remove the bolt.
   1. Release the clamps.
   1. Remove the upper radiator hose.

1. Remove the coolant bypass hose.
   1. Release the clamps.
   1. Remove the coolant bypass hose.

1. Remove the A/C compressor idler pulley and bracket.
   1. Remove the bolts.
   1. Remove the A/C compressor idler pulley and bracket.

1. Position the wire harness aside.
   1. Unclip the wire harness.
   1. Position the wire harness aside.

1. Disconnect the vacuum reservoir vacuum hose.

1. Unclip and reposition the main wire harness.

1. Unclip the wire harness and position aside.

1. Position the wire harness bracket aside.
   1. Unclip the spark plug wire from the bracket.
   1. Remove the bolt.
   1. Position the wire harness bracket aside.

1. Remove the PCV breather hoses and tube.
   1. Release the clamps.
   1. Remove the bolt.
   1. Remove the PCV breather hoses and tube.

1. Remove the upper and lower timing belt covers.
   1. Remove the seven upper timing belt cover bolts.
   1. Remove the upper and lower timing belt covers.

1. NOTE: Note the location of the stud upon removal.
   Remove the water pump.
   1. Remove the six bolts.
   1. Remove the water pump.

Installation

1. NOTE: Apply a 2.0-3.0mm (0.079-0.118 inch) bead of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford Specification WSK-M2G343-A4 to the mounting surface of the water pump.
   

Hello
To replace water pump : Raise the car
1- Drain cooling system. 2- Remove drive belt tensioner clip (if there is one) 3- Remove accessory drivebelt * Rotate the belt tensioner counter clock wise , 3/8 inch square drive bar should do it
* Remove accessory drive belt
4- Lower the car 5- Remove the upper shield. 6- Remove the throttle body. 7- Detch the coolant hose from housing assembly. 8- Remove the upper radiator mounting bracket 9- Detach the hose assembly from the water pump and lower hose. 10- Remove the hose assembly * Detach the hose clips
11- Remove intake manifold support bracket * Detach wiring harness
* Remove intake manifold support bracket
12- Detach coolant hose from water pump 13- Remove coolant hose from the water pump to lower housing. 14- Remove water pump
Installation :
in reverse order and make sure to use new gaskets and seals

(1) No need to know if engine block coolant drain plug was available. Once the water pump was removed, all engine block coolant was drained. (2) After removing the three engine mounting bracket bolts, I also removed the mount bracket from the the body and made enough room to replace the timing belt easier.

The water pump bolts directly to the engine block, using a gasket for pump-to-block sealing, The water pump is driven by the timing belt and is serviced as a unit.Disconnect battery ground cable.Remove crankshaft drive pulleys and torsional damper,and Right Engine Mount & Bracket.Place a jack under engine to support and slightly raise engine, then remove engine mount bracket.
Remove timing belt cover, then mark belt running direction for reinstallation.
Loosen timing belt tensioner, then remove belt and crankshaft sprocket flange shield.
Drain cooling system.
Remove water pump mounting bolts.
Separate water pump from water inlet pipe, then remove water pump.
Reverse procedure to install, noting the following:
Use a new O-ring on water inlet pipe.
Torque water pump mounting bolts to 27 Nm (20 ft. lbs.).

Here's step-by-step instructions on how to access, remove and re-install your alternator. Hope it helps! Have a great day!

Alternator Kia_Sephia_Rio_Spectra_Optima_1998-2006

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the negative battery cable.
3. Temporarily loosen the water pump pulley bolts, 1.6L (VIN 3) engine only.
4. Remove the front air intake inlet pipe bolts, 1.8L engine only.
5. Remove the top hose from the air intake inlet pipe, 1.8L engine only.
6. Remove the air intake inlet pipe clamp and the pipe, 1.8L engine only.
7. Remove the power steering pump, 2.0L engine only.
8. Remove the power steering pump bracket, 2.0L engine only.
9. Remove the alternator B terminal cover cap.
10. Disconnect the alternator electrical connections.
11. Loosen, but do not remove the alternator pivot bolt and the tensioner mounting bolt.
12. Remove the drive belt(s); relieve tension on the belt by rotating the adjustment bolt.
13. Remove the water pump pulley, 1.6L (VIN 3) engine only.
14. Remove the power steering pump, 1.6L (VIN 3) engine only.
15. Remove the power steering pump bracket, 1.6L (VIN 3) engine only.
16. Remove the alternator tensioner mounting bolt and the belt tensioner.
17. Remove the alternator pivot bolt.
18. Loosen the bolt at the base of the adjusting bracket and rotate the bracket up.
19. Remove the alternator. Alternator mounting—1.5L and 1.6L (VIN 5) engine shown Alternator mounting—2.0L and 1.6L (VIN 3) engines shown Alternator mounting—2.4L and 2.7L engine

To install:

1. Before servicing the vehicle, refer to the Precautions Section.
2. Install the alternator.
3. Install the alternator pivot bolt and hand-tighten at this time.
4. Rotate the adjusting bracket into position, place the belt tensioner into position. Hand-tighten the mounting bolt.
5. Install the drive belt.
6. Adjust the belt tension by rotating the adjustment bolt.
7. The belt deflection for 1.5L, 1.6L (VIN 5), 2.4L and 2.7L engines, is as follows:
   1. New belt: 0.22-0.28 in. (5.5-7mm).
   2. Used belt: 0.24-0.28 in. (6-7mm).
8. The belt deflection for 1.6L (VIN 3) engine is as follows :
   1. New belt: 0.13-0.15 in. (3.3-3.7mm).
   2. Used belt: 0.17-0.19 in. (4.2-4.7mm).
9. The belt deflection for the 2.0L engine, is as follows:
   1. New belt: 0.22-0.31 in. (5.5-8mm).
   2. Used belt: 0.33-0.45 in. (8.5-11.5mm).
10. The belt deflection for the 1.8L engine, is as follows:
    1. New belt: 0.23-0.31 in. (6-8mm).
    2. Used belt: 0.28-0.35 in. (7-9mm).
11. Tighten the tensioner bolt to 14-19 ft. lbs. (19-26 Nm) and the pivot bolt to 28-38 ft. lbs. (38-51 Nm).
12. Connect the alternator electrical connections.
13. Install the alternator B terminal cover cap.
14. Install the power steering pump and adjust the power steering belt tension, 2.0L and 1.6L (VIN 3) engines only.
15. Install the water pump pulley, 2006 1.6L engine only.
16. Install the air intake inlet pipe and fasten the clamp, 1.8L engine only.
17. Install the top hose to the air intake inlet pipe, 1.8L engine only.
18. Install the front air intake inlet pipe bolts, 1.8L engine only.
19. Connect the negative battery cable.