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2002 Windstar 3.8L coolant leak appears to be bypass tube next to power steering pump. Hose there doesn't look bad, how to remove tube?

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Posted on Jan 02, 2017

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SOURCE: lower radiator hose connecting tube to water pump.

remove the radiator hose remove the two bolts that hold the tube on and buy new tube and replace is in reverse order.

Posted on Jun 17, 2009

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SOURCE: coolant tubing for rear heat and air leaking

there should be a spliter some where

Posted on Sep 26, 2009

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1 Answer

How to change the thermostat


This is for the 2.7L:

2.7L Engine
  1. Disconnect negative cable.

    CAUTION

    Do not remove pressure cap with the system hot and under pressure because serious burns from coolant can occur.

  2. Drain cooling system.
  3. Remove radiator lower hose from thermostat housing.
  4. Remove nuts from heater tube flange studs.
  5. Loosen starter bolt at heater tube bracket.
  6. Pull heater tube out of thermostat housing and position out of the way.
  7. Remove bolt and two studs.
  8. Remove thermostat housing, O-ring and thermostat.
  9. Remove thermostat housing bolts.

To install:

  1. Clean gasket sealing surfaces.

    NOTE

    Install thermostat with the bleed valve located at the 12 o'clock position, between tabs on seal.

  2. Install thermostat and seal into thermostat housing .
  3. If removed, install two studs.
  4. Install thermostat, thermostat housing and O-ring and bolt. Tighten attaching bolts to 105 inch lbs.(12 Nm).
  5. Lubricate new heater return tube O-ring with coolant.
  6. Position heater return tube flange over two studs. Install nuts.
  7. Tighten retaining nuts to 53 inch lbs.(6 Nm).
  8. Tighten starter bolt to 40 ft. lbs. (54.3 Nm).
  9. Connect the lower radiator hose to the thermostat housing. Install hose clamps.
  10. Refill cooling system.
  11. Inspect for leaks.
  12. Connect negative cable.
This is for the 3.2L and the 3.5L:

3.2L & 3.5L Engines
  1. Disconnect negative cable.

    CAUTION

    Do not remove pressure cap with the system hot and under pressure because serious burns from coolant can occur.

  2. Drain cooling system.
  3. Raise vehicle on hoist.
  4. Disconnect electrical connectors from engine oil and power steering pressure switches.
  5. Disconnect radiator and heater hoses from thermostat housing.
  6. Remove thermostat housing bolts.
  7. Remove housing, thermostat, and gasket.

    NOTE

    The OEM thermostat is staked in place at the factory. To ensure proper seating of replacement thermostat, carefully remove the bulged metal from the thermostat housing using a suitable hand held grinder. It is not necessary to restake the replacement thermostat into the thermostat housing.

To install:

  1. Position gasket on thermostat and housing.
  2. Install thermostat housing, gasket and mounting bolts onto block. Tighten attaching bolts to 105 inch lbs. (12 Nm).
  3. Install radiator hose.
  4. Install bypass hose.
  5. Connect electrical connectors from engine oil and power steering pressure switches.
  6. Connect negative cable.
  7. Fill cooling system.
  8. Inspect for leaks.
  9. Lower vehicle on hoist.

Nov 01, 2010 | 2002 Dodge Intrepid

1 Answer

Can someone help me? am traying to change tha wather pump but want some instructions like what to do first,where the pump is located, and so... thanks!!


5.2L and 5.9L Engines
See Figure 6
  1. Disconnect the negative battery cable.
  2. Open the radiator valve and drain the cooling system.
  3. Remove the cooling fan and shroud as an assembly.
  4. Remove the accessory drive belt.
  5. Remove the water pump pulley from the hub.
  6. Disconnect the hoses from the water pump.
  7. Loosen the heater hose coolant return tube mounting bolt and nut and remove the tube. Discard the O-ring.

3833dec.jpg

Fig. Fig. 6: Water pump mounting bolt locations
  1. Remove the water pump mounting bolts.
  2. Loosen the clamp at the water pump end of the bypass hose. Slip the bypass hose from the water pump while removing the pump from the engine. Discard the gasket.

To install:
  1. Clean all gasket mating surfaces.
  2. Guide the water pump and new gasket into position while connecting the bypass hose to the pump. Tighten the water pump bolts to 30 ft. lbs. (40 Nm).
  3. Install the bypass hose clamp.
  4. Spin the water pump to ensure the pump impeller does not rub against the timing chain cover.
  5. Coat a new O-ring with coolant and install it to the heater hose coolant return tube.
  6. Install the coolant return tube to the engine. Ensure the slot in the tube bracket is bottomed to the mounting bolt. This will properly position the return tube.
  7. Connect the radiator hose to the water pump.
  8. Connect the heater hose and clamp to the return tube.
  9. Install the water pump pulley and tighten the bolts to 20 ft. lbs. (27 Nm).
  10. Install the accessory drive belt.
  11. Install the cooling fan and shroud.
  12. Fill the cooling system.
  13. Connect the negative battery cable.
  14. Start the engine and check for leaks.


Hope helps.

Aug 19, 2010 | 1994 Jeep Grand Cherokee

1 Answer

How do you replace the water pump bypass hose on a 2001 dodge durango 5.9ltr?


I,m assuming you mean the metal part of the bypass hose. Looking at water pump drivers side is a small metal tube hooked to heater hose. The tube is bolted through a alum bracket. Remove bolt and pull tube out. May need to spray with penetrating oil as these corrode, and are stubborn Make sure vehicle is not hot. No need to drain coolant as it will come out of bypass hole. have drain bucket ready. Do not reuse o- ring as it will leak.

Jul 05, 2010 | 2001 Dodge Durango

1 Answer

How to replace a fuel pump on a 1994 jeep grand cherokee?


I'm assuming that your Jeep have a 5.2L V8 engine (as mine), then check this procedure...

Grand Cherokee 5.2L Engines
(see Figure 6)
  1. Disconnect the negative battery cable.
  2. Open the radiator valve and drain the cooling system.
  3. Remove the cooling fan and shroud as an assembly.
  4. Remove the accessory drive belt.
  5. Remove the water pump pulley from the hub.
  6. Disconnect the hoses from the water pump.
  7. Loosen the heater hose coolant return tube mounting bolt and nut and remove the tube. Discard the O-ring.
25b04d0.jpg

Fig. 6: Water pump mounting bolt locations
  1. Remove the water pump mounting bolts.
  2. Loosen the clamp at the water pump end of the bypass hose. Slip the bypass hose from the water pump while removing the pump from the engine. Discard the gasket.
To install:
  1. Clean all gasket mating surfaces.
  2. Guide the water pump and new gasket into position while connecting the bypass hose to the pump. Tighten the water pump bolts to 30 ft. lbs. (40 Nm).
  3. Install the bypass hose clamp.
  4. Spin the water pump to ensure the pump impeller does not rub against the timing chain cover.
  5. Coat a new O-ring with coolant and install it to the heater hose coolant return tube.
  6. Install the coolant return tube to the engine. Ensure the slot in the tube bracket is bottomed to the mounting bolt. This will properly position the return tube.
  7. Connect the radiator hose to the water pump.
  8. Connect the heater hose and clamp to the return tube.
  9. Install the water pump pulley and tighten the bolts to 20 ft. lbs. (27 Nm).
  10. Install the accessory drive belt.
  11. Install the cooling fan and shroud.
  12. Fill the cooling system.
  13. Connect the negative battery cable.
  14. Start the engine and check for leaks.

Other details can find in your repair manual ZJ-Secc-7-Cooling-System

Hope thats help.

May 04, 2010 | 1994 Jeep Grand Cherokee

1 Answer

2006 dodge dakota water pump replacement instructions 3.7L


The water pump can be removed and installed without discharging the air conditioning system (if equipped).

  1. Disconnect battery negative cable.
  2. Drain cooling system. Refer to Draining and Filling found under Cooling System, Service and Repair.
  3. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter.
  4. Remove upper radiator hose clamp and hose at radiator.
  5. The thermal viscous fan drive is attached (threaded) to the water pump hub shaft. Remove fan/viscous fan drive assembly from water pump by turning mounting nut counterclockwise as viewed from front. Threads on viscous fan drive are RIGHT HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) can be used. Place a bar or screwdriver between water pump pulley bolts to prevent pulley from rotating. Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time.
  6. 6. If water pump is being replaced, do not unbolt fan blade assembly from thermal viscous fan drive.
  7. Remove fan shroud attaching hardware (two bolts at bottom-two clips at top).
  8. Remove fan shroud and fan blade/viscous fan drive assembly from vehicle as a complete unit.
  9. After removing fan blade/viscous fan drive assembly, do not place thermal viscous fan drive in horizontal position. If stored horizontally, silicone fluid in viscous fan drive could drain into its bearing assembly and contaminate lubricant.
  10. Do not remove water pump pulley bolts at this time.
  11. Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded automatic tensioner. Relax tension from belt by rotating tensioner clockwise (as viewed from front). When all belt tension has been relaxed, remove accessory drive belt.
  12. 12. Remove four water pump pulley-to-water pump hub bolts and remove pulley from vehicle.
  13. Remove lower radiator hose clamp and remove lower hose at water pump.
  14. Remove heater hose clamp and heater hose from heater hose coolant return tube.
  15. Loosen heater hose coolant return tube mounting bolt and remove tube from water pump. Discard the old tube O-ring.
  16. Remove seven water pump mounting bolts.
  17. Loosen clamp at water pump end of bypass hose. Slip bypass hose from water pump while removing pump from vehicle. Discard old gasket. CAUTION: Do not pry water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks.

INSTALLATION

  1. Clean gasket mating surfaces.
  2. Using a new gasket, install water pump to engine as follows: Guide water pump nipple into bypass hose as pump is being installed. Install water pump bolts. Tighten water pump mounting bolts to 40 Nm (30 ft. lbs.) torque.
  3. Position bypass hose clamp to bypass hose.
  4. Spin water pump to be sure that pump impeller does not rub against timing chain case/cover.
  5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation.
  6. Install coolant return tube and its mounting bolt to engine. Be sure the slot in tube bracket is bottomed to mounting bolt. This will properly position return tube.
  7. Connect radiator lower hose to water pump.
  8. Connect heater hose and hose clamp to coolant return tube.
  9. Install water pump pulley. Tighten bolts to 27 Nm (20 ft. lbs.) torque. Place a bar or screwdriver between water pump pulley bolts to prevent pulley from rotating.
  10. Relax tension from belt tensioner. Install accessory drive belt.
  11. CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to Illustration above for correct belt routing. The correct belt with correct length must be used.
  12. Position fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit.
  13. Install fan shroud.
  14. Install fan blade/viscous fan drive assembly to water pump shaft.
  15. Fill cooling system.
  16. Connect battery negative cable.
  17. Start and warm the engine. Check for leaks.

Feb 28, 2010 | 2006 Dodge Dakota

1 Answer

Replacing a water pump on a ford windstar how do i do it?


Removal

1. Disconnect the battery ground cable.

2. Drain the cooling system. For additional information.

3. Remove the accessory drive belt.

4. Raise and support the vehicle.

5. Disconnect lower radiator hose from the water pump lower tube.

6. Remove the engine mount nuts.

Lower the vehicle.

7. Remove the cowl extension panel. (Thats theone with the wiper arms go through).

8. Disconnect the water bypass hose and the heater hose from the water pump outlet tube.

9. Remove the water pump outlet tube bolt and position the tube assembly out of the way.

10. Install the lifting eye to the exhaust manifold.

11. Attach engine lifting equipment and raise the engine 127 mm (5 inches).

12. Remove the bolt and the accessory belt idler pulley.

13. Remove the bolts and the generator support bracket.

14. Remove the four bolts and the water pump pulley.

15. Remove the water pump. Remove the five nuts. Remove the five studs.
Remove the four bolts. Remove the water pump, lower tube and gasket as an assembly.

Feb 22, 2010 | 2002 Ford Windstar Cargo

1 Answer

My 2002 ford windstar has a leak comming from the pipe thats connected to the water pump and now my belt has broken and the waterpump I believe is frozen. can a waterpump freeze from having water put into...


i think your water pump is done for. replace pump and the belt and you should be good to go. that lower pipe always rotts out on these vans. might want to replace the coolant bypass hose on top while your at it. it tends to brake around the same time as the lower pipe

Feb 15, 2010 | 2000 Ford Windstar

1 Answer

What might be the source of an antifreeze leak? It appears to be coming from the engine front up and to the left of the oil filter on my V6, '95 Camry. I find the small puddle after the car has stopped,...


yes it could be a bypass hose it could be a freeze out plug going bad it may be a bad head gasket it may be a bad water pump these are a few items to check.

Jan 28, 2010 | 1995 Toyota Camry

3 Answers

2001 Ford Windstar is leaking antifreeze


Could be water pump, radiator, freeze plugs, hoses, ect. try and isolate the area by putting a piece of card board down on the ground and line up what is above it. Garages use a pressure tester on the cooling system to see where the leak is. I would guess water pump,or small bypass hose

May 23, 2009 | 2001 Ford Windstar

1 Answer

Removal and installation of the water pump


3.0L or 3.8L engine?

please rate as fixed if this solves your issue.

Section 03-01B: Engine, 3.8L 1996 Windstar Workshop Manual
IN-VEHICLE SERVICE Water Pump SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Fuel Line Disconnect Tool Set T90T-9550-S
Removal
  1. Drain engine cooling system. Refer to Section 03-03 .
  1. Loosen drive belt tensioner (6B209) and remove drive belt (8620). Refer to Section 03-05 .
  1. Raise vehicle on hoist. Refer to Section 00-02 .
  1. Disconnect lower radiator hose (8286) from radiator lower hose tube (8291) and radiator (8005).
  1. Disconnect radiator lower hose tube from water pump (8501).
  1. Remove lower nut on both front engine support insulators (6038).
  1. Lower vehicle.
  1. Disconnect battery ground cable (14301). Refer to Section 14-01 .
  1. Remove generator (GEN) (10346) from power steering pump support (3C511).
  1. Position drain pan and disconnect power steering pressure line from power steering pump (3A674) using Fuel Line Disconnect Tool Set T90T-9550-S.
  1. Remove power steering reservoir filler cap.
  1. stw~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: If using a prying device to assist in water pump removal, be careful not to damage the mating surfaces.
    Disconnect water bypass hose (8597) and oil cooler hose (6B850) from heater water outlet tube (18663).
  1. Remove retaining bolts and disconnect heater water outlet tube from water pump.
  1. Remove A/C bracket brace.
  1. Attach engine lifting eye to left-hand (front) exhaust manifold (9430).
  1. Attach lifting equipment to engine lifting eye and raise front of engine approximately 51 mm (2.0 inches) to provide necessary clearance for water pump removal.
  1. Remove water pump pulley retaining bolts and water pump pulley (8509).
  1. Remove drive belt tensioner pulley retaining bolt and drive belt tensioner pulley (6B217) from power steering pump support.
  1. Remove power steering pump support retaining bolts and nut. Place power steering pump and support assembly aside in a position to prevent fluid leakage.
  1. Remove water pump retaining bolts and nuts and water pump. Discard used water pump housing gasket (8507).
Installation
  1. NOTE: Lightly oil all bolt and stud bolt threads before installation except those specifying special sealant.

    Clean gasket surfaces on water pump and engine front cover (6019).
  1. NOTE: The threads of the No. 1 engine front cover retaining stud must be coated with Pipe Sealant with Teflon® D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 before installing.

    NOTE: Gasket and Trim Adhesive D7AZ-19B508-B or equivalent meeting Ford specification ESE-M2G52-A is recommended to hold the water pump housing gasket in position.

    Position a new water pump housing gasket on water pump housing sealing surface.
  1. Position water pump on the engine front cover. Install retaining bolts.
  1. Position power steering pump support and install retaining nuts and bolts. Tighten bolts and nuts to 40-55 Nm (30-40 lb-ft).
  1. Install drive belt tensioner pulley and retaining bolt. Tighten bolt to 70-95 Nm (52-70 lb-ft).
  1. Install A/C bracket brace.
  1. Position water pump pulley on water pump hub and install retaining bolts. Tighten bolts to 8.0-11.5 Nm (71-101 lb-in).
  1. Lower engine and disconnect lifting equipment from lifting eye.
  1. Remove lifting eye from exhaust manifold.
  1. Connect heater water outlet tube to water pump and install retaining bolts. Tighten bolts to 8-11.5 Nm (71-101 lb-in).
  1. Connect water bypass hose and oil cooler hose to heater water outlet tube. Tighten clamps securely.
  1. Connect power steering pressure line to power steering pump fitting.
  1. Install power steering reservoir filler cap.
  1. Install generator to power steering pump support. Refer to Section 14-02 .
  1. Connect battery ground cable. Refer to Section 14-01 .
  1. Raise vehicle on hoist. Refer to Section 00-02 .
  1. Install lower nut on front engine support insulators and tighten retaining nut to 88-119 Nm (65-87 lb-ft). Install lower nut of rear engine support insulator and tighten to 77-104 Nm (56-76 lb-ft).
  1. Connect radiator lower hose tube to water pump. Install retaining bolt and tighten securely.
  1. Connect lower radiator hose to radiator lower hose tube and radiator. Position hose clamps securely. Refer to Section 03-03 .
  1. Lower vehicle.
  1. Position drive belt over drive belt tensioner and release drive belt tensioner. Refer to Section 03-05 .
  1. stw~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: This engine has aluminum cylinder heads (6049) and requires a special corrosion inhibiting coolant to avoid cooling system damage. Refer to Section 03-03 for the coolant specifications.
    Fill and bleed cooling system with specified coolant.
  1. Fill power steering pump reservoir with specified fluid.
  1. Start engine and check for coolant and power steering fluid leaks. Service as necessary.


    Water Pump
581f50d.gif

Apr 13, 2009 | 1996 Ford Windstar

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