1989 Caddilac Brougham 5.0 L engine with carburetor. During water pump installation the bolt that connects the power steering pump to the engine block is not threading. The 1 and a half inch bolt would not go into the hole more than a quarter inch. Something in the engine seems to be partially blocking the opening. HELP! HELP !!!!!!!!!!

Power Steering Pump - 4.0L Special Tool(s) Installer Set, Teflon® Seal
211-D027 (D90P-3517-A) or equivalent Material Item Specification MERCON® V Automatic Transmission Fluid
XT-5-QM (or XT-5-QMC) (US); CXT-5-LM12 (Canada) MERCON® V
Item Part Number Description 1 388898 Teflon® seal 2 - Pressure line-to-pump fitting (part of 3A719) 3 W700839 Power steering pump bolts (3 required) 4 3A674 Power steering pump 5 W503924 Pressure line bracket-to-engine bolt 6 3691 Power steering pump supply hose 7 W503924 Power steering pump supply hose bracket bolt
Removal
NOTICE: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result.

1. Using a suitable suction device, remove the power steering fluid from the reservoir.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.

1. Remove the power steering pump pulley. For additional information, refer to Power Steering Pump Pulley - 4.0Lin this section.

1. Remove the pressure line bracket-to-engine bolt.

1. Remove the power steering pump supply hose bracket bolt.

1. Release the power steering pump supply hose clamp and disconnect the hose.

1. Disconnect the pressure line-to-pump fitting.
   • Remove and discard the Teflon® seal.

1. Remove the 3 bolts and the power steering pump.

Installation

1. NOTE:A new Teflon® seal must be installed.Using the Teflon® Seal Installer Set, install a new Teflon® seal to the pressure line fitting.

1. Position the power steering pump and install the 3 bolts.
   • Tighten to 25 Nm (18 lb-ft).

1. Connect the pressure line-to-pump fitting.
   • Tighten to 75 Nm (55 lb-ft).

1. Connect the power steering pump supply hose.

1. Install the power steering pump supply hose bracket bolt.
   • Tighten to 11 Nm (97 lb-in).

1. Install the pressure line bracket-to-engine bolt.
   • Tighten to 11 Nm (97 lb-in).

1. Install the power steering pump pulley. For additional information, refer to Power Steering Pump Pulley - 4.0Lin this section.

1. Fill the power steering system. For additional information, refer to Section 211-00.

Belt Installation, Aerostar 4.0L Engine





Item Part Number Description 1 8620 Drive Belt 2 N606068 Bolt 3 10300 Generator 4 10153 Generator Mounting Bracket 5 8509 Water Pump Pulley 6 6B209 Drive Belt Tensioner 7 N800199 Screw 8 8678 Belt Idler Pulley 9 N802096 Screw 10 19703 A/C Compressor 11 2882 A/C Compressor Mounting Bracket 12 3C718 Brace 13 N806020 Bolt 14 3A674 Power Steering Pump 15 3A733 Power Steering Pump Pulley 16 N800199 Screw 17 N606572 Bolt 18 N620481 Nut 19 8501 Water Pump 20 6312 Crankshaft Pulley A - Belt Tension Check (See Specifications) B - Tighten to 40-55 Nm
(30-41 Lb-Ft) C - Tighten to 24-30 Nm
(18-23 Lb-Ft) D - Tighten to 21-29 Nm
(15-21 Lb-Ft) E - Tighten to 40-50 Nm
(30-37 Lb-Ft)

Belt Installation, Ranger and Explorer 4.0L Engine





Item Part Number Description 1 8620 Drive Belt 2 10300 Generator 3 8678 Belt Idler Pulley 4 19703 A/C Compressor 5 3A733 Power Steering Pump Pulley 6 8501 Water Pump 7 6312 Crankshaft Pulley 8 6B209 Drive Belt Tensioner 9 N806020 Bolt 10 2882 A/C Compressor Mounting Bracket 11 3A674 Power Steering Pump 12 N606572-S2 Bolt 13 N800199-S8M Bolt 14 N620481-S2 Nut 15 3C718 Brace 16 N606068 Bolt 17 10153 Generator Mounting Bracket 18 8509 Water Pump Pulley 19 N605805-S2 Bolt A - Belt Tension Check (See Specifications) B - Tighten to 21-29 Nm
(15-21 Lb-Ft) C - Tighten to 40-55 Nm
(30-41 Lb-Ft)

Belt Installation, Ranger 2.3L Engine





Item Part Number Description 1 8678 Belt Idler Pulley 2 10300 Generator 3 8509 Water Pump Pulley 4 3A733 Power Steering Pump Pulley 5 2E884 A/C Clutch Pulley 6 6312 Crankshaft Pulley

Belt Installation, Aerostar 3.0L Engine





Item Part Number Description 1 10300 Generator 2 3F671 Belt Idler Pulley 3 3A733 Power Steering Pump Pulley 4 6B209 Drive Belt Tensioner 5 6312 Crankshaft Pulley 6 8509 Water Pump Pulley 7 19703 A/C Compressor

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

    Fig. Alternator mounting-1.5L and 1.6L (VIN 5) engine shown
    
    
    

    Fig. Alternator mounting-2.0L and 1.6L (VIN 3) engines shown
    
    
    

    Fig. 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.

Section 11-02A: Steering Pump, Power, C-II 1996 Aerostar, Ranger and Explorer Vehicles Workshop Manual REMOVAL AND INSTALLATION Pump and Pulley SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Steering Pump Pulley Remover T69L-10300-B Steering Pump Pulley Replacer T65P-3A733-C
Removal

1. Disconnect the power steering return hose (3A713) at the pump and drain fluid.
   

1. Remove the power steering pressure hose (3A719) by unscrewing connector from the pump.
   

1. On the Aerostar 3.0L V-6 engine (6007), loosen the drive belt tensioner (6B209) and adjustment bolts.
   
   
   
   
   
   Item Part Number Description 1 10346 Generator 2 8501 Water Pump 3 8678 Belt Idler Pulley 4 3A733 Power Steering Pump Pulley 5 6303 Crankshaft 6 2884 A/C Clutch 7 — Without A/C On the 2.3L I-4 and 4.0L V-6 engines, slacken belt tension by lifting drive belt tensioner in a counterclockwise direction. On Ranger 3.0L V-6 engines, slacken belt tension by lifting drive belt tensioner in a clockwise direction. Remove drive belt (8620) from under drive belt tensioner and slowly lower pulley to stop. Remove the drive belt from the power steering pump pulley (3A733).
   
   
   
   
   
   Item Part Number Description 1 10346 Generator 2 2884 A/C Clutch 3 3A733 Power Steering Pump Pulley 4 8501 Water Pump 5 6303 Crankshaft 6 8678 Belt Idler Pulley 7 6B209 Drive Belt Tensioner

1. NOTE: If the drive belt requires servicing, refer to Section 03-05 .
   
   Remove the drive belt from the power steering pump pulley.
   

1. Remove the oil dipstick tube.
   

1. Remove the power steering pump support (3C511).
   

1. Install Steering Pump Pulley Remover T69L-10300-B on the pulley.
   

1. NOTE: Do not apply pressure on the power steering pump rotor shaft (3B559). Pressure will damage internal thrust areas of the power steering pump (3A674).
   
   While holding the remover tool nut stationary with a wrench, rotate the inner spindle of the remover tool clockwise until the pulley is pulled off the power steering pump rotor shaft.
   

1. Remove the bolts attaching the power steering pump to the A/C compressor mounting bracket (2882).
   

Installation

1. Install the power steering pump on the A/C compressor mounting bracket. Install and tighten attaching bolts to 41-61 Nm (30-45 lb-ft). On 4.0L engine, tighten to 47-64 Nm (35-47 lb-ft).
   

1. Position the support on the A/C compressor mounting bracket. Install mounting bolts and tighten to 47-64 Nm (35-47 lb-ft).
   

1. NOTE: Fore/aft location of power steering pump pulley on power steering pump rotor shaft is critical. Incorrect belt alignment may cause drive belt squeal or chirp. Make sure pull-off groove on power steering pump pulley is facing front and flush with end of shaft ± 0.254mm (± 0.010 inch).
   
   Install the Steering Pump Pulley Replacer T65P-3A733-C and install the power steering pump pulley.
   

1. Install the drive belt on the power steering pump pulley.
   

1. On the 2.3L I-4, Ranger 3.0L V-6, and 4.0L V-6 engines, position and rotate drive belt on engine. While lifting drive belt tensioner in a counterclockwise direction (clockwise on Ranger 3.0L V-6), slide drive belt under drive belt tensioner and lower drive belt tensioner to drive belt.
   On Aerostar 3.0L V-6 engine, position the belt idler pulley (8678) assembly to give the drive belt the tension specified. Refer to belt tension check in Section 03-05 . Tighten the drive belt tensioner and adjustment bolts to 47-64 Nm (35-47 lb-ft).
   

1. Install the power steering pump support, if removed.
   

1. Install the oil dipstick tube.
   

1. Install the pressure hose tube nut and new Teflon® wagner into power steering pump valve outlet fitting (3D654) and tighten to 41-54 Nm (30-40 lb-ft).
   

1. Connect the power steering return hose to the power steering pump, and reposition the clamp.
   

1. Fill the power steering oil reservoir (3A697) with Premium Power Steering Fluid E6AZ-19582-AA or equivalent fluid meeting specification ESW-M2C33-F. Start the engine and turn the steering wheel (3600) from left to right without hitting stops to remove air from the system.
   

1. Check for leaks and recheck the fluid level. Add fluid if necessary to proper level as specified in Section 11-00 .
   
   
   Power Steering Pump and Power Steering Pulley, 2.3L TPH Engine, Ranger Only
   
   
   
   
   
   Item Part Number Description 1 2882 A/C Compressor Mounting Bracket 2 N606543-S2 Bolt (2 Req'd) 3 N606069-S2 Bolt (2 Req'd) 4 N605803-S2 Bolt 5 N800199-S8M Screw 6 3D673 Power Steering Pump Pulley 7 3F671 Power Steering Belt Idler Support 8 N806020-S2 Bolt 9 3A674 Power Steering Pump 10 19703 A/C Compressor A — Tighten to 21.2-29 Nm (16-21 Lb-Ft) B — Tighten to 40.3-55 Nm (30-41 Lb-Ft) C — Tighten to 44-51 Nm
   (32-38 Lb-Ft)
   
   Power Steering Pump and Power Steering Pulley, 3.0L Engine, Aerostar
   
   
   
   
   
   Item Part Number Description 1 3A674 Power Steering Pump 2 3C511 Power Steering Pump Support 3 6007 Engine 4 N803564 Stud 5 N802827-S2 Nut 6 N800199-S8M Screw (3 Req'd) 7 N8011179-S2 Screw (3 Req'd) 8

GM Astro/Safari 1985-1996 Repair Guide
Power Steering Pump - REMOVAL & INSTALLATION
(see Figures 1, 2, 3, 4, 5, 6 and 7)



Fig. 1: Exploded view of the power steering pump assembly mounting-2.5L engine



Fig. 2: Exploded view of the power steering pump assembly mounting-early-model 4.3L engine



Fig. 3: Removing the power steering pump pulley-1985-92 vehicles



Fig. 4: Installing the power steering pump pulley



Fig. 5: Pump pulley removal and installation-1993-96 vehicles



Fig. 6: Exploded view of the power steering pump mounting-late-model 4.3L engines (1993-96 shown)



Fig. 7: Typical power steering pump hose routing-1996 shown


The following procedure requires the use of the GM Puller tool No. J-29785-A (1985-92), Puller J-25034-B (1993-96) or equivalent, and the GM Pulley Installer tool No. J-25033-B or equivalent.

1. Disconnect the negative battery cable for safety.
2. For 1996 vehicles, remove the air cleaner assembly for access.
3. For 1993-96 vehicles, remove the hood latch and the upper fan shroud.
4. Release tension and remove the drive belt.
5. Remove the power steering pump pulley using a suitable puller tool.
6. Remove the power steering pump retaining bolts, then reposition the pump as necessary for access to the hoses.
7. Position a fluid catch pan under the power steering pump.
8. Remove the hoses from the power steering pump and drain the excess fluid into the catch pan.

WARNING Be sure to cap all openings in the pump hydraulic system to prevent excessive fluid spillage and the possibility of system contamination.

1. Remove the power steering pump from the vehicle.
   

To install:

1. Position the pump to the vehicle, then uncap and connect the pump hoses.
2. Install the steering pump to the retaining bracket, then secure using the retaining bolts. Tighten the power steering pump-to-bracket bolts to 37 ft. lbs. (50 Nm). For 1996 vehicles, tighten the nut to 30 ft. lbs. (41 Nm).
   

On early-model vehicles where the drive belt is tensioned by pivoting the power steering pump assembly, do NOT fully tighten the mounting bolts at this time, since you will just have to loosen them again for belt installation and adjustment.

1. Install the pump pulley using the GM Pulley Installer tool No. J-25033-B or equivalent. Press the drive pulley onto the power steering pump.
2. Hand-tighten the pivot bolt, the adjusting bolt and the washer.
3. Install the drive belt. On early-model vehicles so equipped, properly adjust the belt tension. For details on belt installation and tension adjustment.
4. For 1993-96 vehicles install the upper fan shroud and the hood latch assembly.
5. For 1996 vehicles, install the air cleaner assembly.
6. Connect the negative battery cable.
7. Refill the power steering reservoir and bleed the power steering system.
8. Remove the jackstands and carefully lower the vehicle.
9. Road test the vehicle, then check and top-off the power steering fluid.

hope this help (remember rated this post) Good luck.

I can sell you a shop manual ans wiring book for $25 plus postage or you can go to our website.

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1. Drain the cooling system. Refer to Section 03-03 for the procedure.
   

1. Disconnect the battery ground cable (14301).
   

1. Remove the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05 for the removal procedures.
   

1. Raise and support the vehicle.
   

1. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley (8509) while removing the four water pump pulley bolts.
   
   
   
   
   

1. Remove the water pump pulley from the water pump (8501).
   

1. Remove the crankshaft pulley (6312). Refer to the procedure in this section.
   

1. Remove the five lower engine front cover bolts and the lower engine front cover (6019).
   
   
   
   
   

1. NOTE: Make a note of the location of the one water pump stud/bolt for ease of installation.
   
   Remove the six water pump bolts.
   
   
   
   
   

1. Remove the water pump.
   

Installation

1. NOTE: Ensure the mating surfaces between the water pump and the cylinder block (6010) are cleaned of any sealant material.
   
   Install a continuous 2.0-3.0mm (0.079-0.118 inch) wide bead of Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A5, on the water pump and position the water pump on the cylinder block.
   
   
   
   
   

1. NOTE: Refer to the note made during removal for the location of the stud/bolt.
   
   Install the six water pump bolts. Tighten the water pump bolts to 16-21 Nm (12-15 lb-ft).
   

1. Position the water pump pulley on the water pump and install the four water pump pulley bolts.
   

1. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley, and tighten the four water pump pulley bolts to 16-21 Nm (12-15 lb-ft).
   

1. Install the lower engine front cover and the five lower engine front cover bolts. Tighten the five lower engine front cover bolts to 3-5 Nm (27-44 lb-in).
   

1. Install the crankshaft pulley. Refer to the procedure in this section.
   

1. Lower the vehicle.
   

1. Install and adjust the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05 for the installation and adjustment procedures.
   

1. Connect the battery ground cable.
   

1. Fill the cooling system. Refer to Section 03-03 for the procedure.
   

1. Start the engine (6007) and check for leaks.
   

Removal & Installation

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.
    
    Fig. Alternator mounting-1.5L and 1.6L (VIN 5) engine shown
    
    
    Fig. Alternator mounting-2.0L and 1.6L (VIN 3) engines shown
    
    
    Fig. 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.

go here too http://autos.groups.yahoo.com/group/villagerquest/ Section 03-01: Engine 1996 Villager Workshop Manual IN-VEHICLE SERVICE -------------------------------------------------------------------------------- Water Pump Removal Water Pump Removal Drain the cooling system. Refer to Section 03-03 for the procedure. Disconnect the battery ground cable (14301). Remove the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05 for the removal procedures. Raise and support the vehicle. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley (8509) while removing the four water pump pulley bolts. Remove the water pump pulley from the water pump (8501). Remove the crankshaft pulley (6312). Refer to the procedure in this section. Remove the five lower engine front cover bolts and the lower engine front cover (6019). NOTE: Make a note of the location of the one water pump stud/bolt for ease of installation. Remove the six water pump bolts. Remove the water pump. Installation NOTE: Ensure the mating surfaces between the water pump and the cylinder block (6010) are cleaned of any sealant material. Install a continuous 2.0-3.0mm (0.079-0.118 inch) wide bead of Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A5, on the water pump and position the water pump on the cylinder block. NOTE: Refer to the note made during removal for the location of the stud/bolt. Install the six water pump bolts. Tighten the water pump bolts to 16-21 Nm (12-15 lb-ft). Position the water pump pulley on the water pump and install the four water pump pulley bolts. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley, and tighten the four water pump pulley bolts to 16-21 Nm (12-15 lb-ft). Install the lower engine front cover and the five lower engine front cover bolts. Tighten the five lower engine front cover bolts to 3-5 Nm (27-44 lb-in). Install the crankshaft pulley. Refer to the procedure in this section. Lower the vehicle. Install and adjust the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05 for the installation and adjustment procedures. Connect the battery ground cable. Fill the cooling system. Refer to Section 03-03 for the procedure. Start the engine (6007) and check for leaks.

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. 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. 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
   

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.