How to Replace the Water Pump on a 3.8L 93 Taurus

The water pump on a 1993 Ford 3.8-liter Taurus is an externally mounted unit driven by a serpentine belt. An automatic spring-loaded tensioner supplies the belt tension. A water pump that has failed shows signs of water leaking through a hole in the bottom of the water pump snout, called a weep hole. Another indication is a wobbling water pump pulley. When the water pump is replaced with a rebuilt pump, the old pump is used for a core.

Instructions

Removal

1

Disconnect the negative battery terminal using a wrench. Place the drain pan under the radiator and drain the radiator by opening the drain valve with pliers. Remove the radiator cap to allow the system to drain faster.

2

Search for a serpentine belt routing diagram on the radiator support. If it is not present, draw the routing for reference to aid in installation. Place a wrench on the belt tensioner pulley bolt and swing the tensioner away from the belt. Remove the serpentine belt.

3

Remove the two nuts and bolt securing the tensioner to the engine block with the use of a socket and ratchet. Squeeze the spring clamp securing the heater hose to the water pump using pliers and pull the hose off.

4

Remove the water pump pulley bolts using a wrench. The pulley must stay on the pump snout and come out with the pump because of a lack of clearance between the pump and frame.

5

Remove all the water pump retaining bolts and nuts using a socket and ratchet. It is very important to make a note of the location on the pump of each of the bolts. They are different lengths and each bolt must be installed in the same spot from where it was removed. A bolt that is too long for its location can damage a cylinder liner. Lift the pump and pulley out of the engine compartment.

Installation

6

Clean all the bolt and stud threads with a rag. Lightly coat the threads with oil. Scrape all the remaining gasket material off the contact surface of the block. Wipe the surface so its perfectly smooth to prevent any possible leaks.

7

Coat both sides of the new water pump gasket with RTV silicone sealant and place the gasket on the new water pump. Place the water pump pulley on the water pump snout, leaving it loose. Position the water pump over the studs in the block and install the bolts in their original positions. Install the nuts on the studs. Torque the retaining bolts 15 to 22 foot-pounds.

8

Install the water pump pulley bolts and torque them to 16 foot-pounds. Squeeze the spring clamp on the heater hose and push the hose on the water pump. Place the serpentine belt on all the pulleys except the tensioner. Move the tensioner away from the belt and install the belt.

9

Close the radiator drain and remove the drain pan. Connect the negative battery terminal. Remove the radiator cap and fill the radiator with the 50-50 mixture of antifreeze and water.

10

Start the engine and allow it to reach normal operating temperature. Leave the cap off the radiator during the warmup. Keep topping off the radiator as air is expelled and the coolant level drops. When the engine reaches normal operating temperature of 195 degrees, the thermostat will open and allow coolant to flow through the radiator. The hose will become hot as this occurs, the coolant level will drop and coolant can be seen in the filler neck flowing out of the top cores.

11

Top off the radiator coolant level and install the radiator cap. Fill the coolant reservoir to the "full" mark with the 50-50 mixture of antifreeze and water. Check for leaks.