Attachment III - Technical Information
AFFECTED VEHICLESCERTAIN 1998 CONTOUR AND MYSTIQUE VEHICLES EQUIPPED WITH 2.0L ZETEC ENGINES
REMOVAL
1. Install a memory saver.
2. Disconnect the battery ground cable.
WARNING
WHEN RELEASING THE SYSTEM PRESSURE, COVER THE EXPANSION TANK CAP WITH A THICK CLOTH TO PREVENT THE POSSIBILITY OF COOLANT SCALDING. FAILURE TO FOLLOW THESE INSTRUCTIONS WILL RESULT IN PERSONAL INJURY.
3. Relieve the cooling system pressure by unscrewing the cap slowly, then remove the cap.
4. Raise and support the vehicle.
5. Remove the radiator splash shield, if equipped.
6. Remove the drain plug from the radiator and drain the cooling system into a suitable container.
7. Replace the drain plug when all coolant has drained.
8. Partially lower the vehicle.
9. Remove the right front wheel assembly.
10. Remove the RH lower splash shield.
11. Loosen the water pump pulley bolts.
12. Rotate the accessory drive belt tensioner clockwise and remove the belt.
13. Using Strap Wrench D85L-6000-A to prevent the engine from rotating, remove the crankshaft pulley.
14. Remove the water pump pulley.
15. Remove the four (4) water pump bolts.
16. Remove the water pump.
INSTALLATION
1. Clean the water pump housing mating surface.
2. Position the water pump and install the bolts. Tighten the bolts to 10 Nm (8 lb-ft).
3. Position the water pump pulley and install the bolts finger-tight.
4. Raise and support the vehicle.
5. Install the crankshaft pulley and tighten the bolts to 115 Nm (85 lb-ft).
6. Rotate the belt tensioner clockwise and install the accessory drive belt.
7. Tighten the water pump pulley bolts to 24 Nm (18 lb-ft.).
8. Install the radiator splash shield, if equipped.
9. Install the RH lower splash shield.
10. Install the wheel assembly.
11. Lower the vehicle.
12. Connect the battery ground cable and remove the memory saver.
13. Fill the expansion tank to the MAX mark.
14. Start the engine and run until normal operating temperature is achieved. Check for leaks and add coolant if necessary.