How remove front cover on pump to see if blocked? - servis m6666

• Tools Required
• J 43651 Water Pump Holding Tool
• Remove the thermostat housing.
• Remove the water pump access plate from the front cover.
• Remove the right hand fender liner.
1. Important: A drain plug has been provided at the bottom of the water pump assembly for additional coolant drainage from the engine block and water pump.
Drain the coolant from the water pump using the plug at the bottom of the pump.

1. mportant: The water pump holding tool supports the sprocket and chain during water pump service. The tool must be used or the balance shaft must be re-timed.
Install the J 43651 into position.

1. Tighten the bolts on the water pump holding tool into the threads on the water pump sprocket.
2. Install the access cover bolts that were removed earlier to secure the water pump holding tool to the front cover assembly.
3. Remove the 3 inner water pump sprocket to water pump blots.
1. Important: Be sure to remove both water pump bolts from the front of the engine block.
Remove the 2 water pump bolts.
Remove the rear 2 water pump bolts.

1. Remove the water pump.
2. Remove and discard the water pump O-ring seal.
Installation Procedure

1. Important: Prior to installing the water pump, read the entire procedure. This will help avoid balance shaft chain re-timing and ensure proper sealing.
Install a NEW water pump O-ring seal.


1. Important: A guide pin can be created to aid in water pump alignment. Use a M 6 m x 6 mm stud. Thread the pin into the water pump sprocket.
Using the guide pin, align the pin with the water pump holding tool.

1. Position the water pump against the engine block and hand tighten the water pump bolts.
2. Notice: Refer to Fastener Notice.
Install the inner water pump sprocket bolts. After 2 are snug, remove the guide pin and install the 3rd bolt.
Tighten the bolts to 25 Nm (18 ft. lbs.).

1. Tighten the water pump sprocket bolts last. Tighten the bolts to 10 Nm (89 inch lbs.).
2. Remove the J 43651.
3. Install the water pump access plate and bolts. Tighten the bolts to 10 Nm (89 inch lbs.).
4. Install the right hand fender liner.
5. Install the thermostat housing.

no, here is the procedure. Please let me know if you have more questions.

REMOVAL & INSTALLATION

2.2L Engine

1. Remove the serpentine belt and tensioner.
   

Although not absolutely necessary, removal of the right front inner fender splash shield will facilitate access to the front cover.

1. Install a suitable engine support fixture.
2. Remove the engine mount assembly.
3. Remove the alternator rear brace, then remove the alternator.
4. Remove the power steering pump, then position it aside with the lines still attached.
5. Raise and safely support the vehicle.
6. Remove the front two oil pan bolts.
7. Remove the crankshaft pulley.
8. Unfasten the front cover-to-block bolts and then remove the front cover. If the front cover is difficult to remove, use a plastic mallet to carefully loosen the cover.

Hi, there is a round cover on the front left corner. Install a pick in the small hole and turn the cover. You will see a twist cap behind the cover. Unscrew the cap and remove what ever is blocking the pump from turning. Watch out because the water in the tub will drain out.

That should fix the problem....

Water pump is driven by timing chain idler and is mounted on the rear of the timing chain housing. Disconnect the neg. battery cable. Drain cooling system. Disconnect oxygen sensor connector.
Remove upper exhaust manifould heat sheild. Remove exhaust manifold brace. Remove lower exhaust manifold heat sheild. Loosen manifold to exhaust manifold spring loaded nuts. Remove radiator outlet pipe to water pump coverbolts. Disconnect exhaust pipe from manifold.
Pull down on the exhaust pipe to disconnect it from exhaust manifold bolts. Disconnect outlet pipe from oil pan and transaxle. If equipped with manual tranaxle, remove exhaust maifold brace. Leave lower radiator hose attached and pull down on radiator out look pipe to disengauge from water pump. Leave outlet pipe hanging.
Lower vehicle. Remove exhaustmanifold to cylinder head nuts. Remove exhaust manifold to cylinder head nuts. Remove manifould. Remove timing chain front cover. Remove timing chain tensioner. Remove bolts bolts securing water pump cover to cylinder block. Remove water pump to timing chain housing nuts. Remove water pump attaching nuts. Remove water pump and cover assembly. Separate componets as necessary.
WHEN INSTALLING WATER PUMP MAKE SURE YOU FOLLOW THE TIGHTENING SEQUENCES THAT AFFECT SEALING. My frist one I messed up and broke the pump so becarful.
Installation
If cover was separated from body during removal, join this componets with a new gasket and hand tighten bolts. Apply bearing grease to splines of water pump drive. Set body and assemble into position.
Install and hand tighten bolts securing cover to cylinder block. Install and hand tighten bolts securing cover to cylinder block. Installand hand tighten nuts securing body to timing chain housing. Lubracate outlet pipe "O" ring with antifreeze. (I use RTV) Connect outlet pipe. Install and hand tighten bolts. Tighten bolts and nuts to specification in the following sequence. I'll ad the torque spec. at the end but this is where if you tighten out of order something will break.
pump assembly to timing chain housing nuts.
pump cover to pump body bolts
pump cover to cylinder block bolts (Bottom Bolt First)
outlet pipe to cover bolts
To complete installation reverse removel procedure.
Torque specs are 19 in. or 26mm all except water pump cover bolts which are 124 in or 14Nm
I never torque the bolts just make sure there done in the right order.

There are two oil pumps; the Main Oil Pump and the Scavenger Oil Pump. I will list the procedure for both pumps.

Main Oil Pump

1) Put the bike up on the center stand
2) Remove the engine front cover
3) Remove the collar and O-ring seals from the oil pump cover
4) Remove the bolts and Phillips screws holding the oil pump cover on and remove the cover
5) Remove the dowel pins from the oil pump body
6) Remove the inner and outer rotors
7) Remove the drive pin and washer from the drive shaft and remove the oil pump body from the cylinder block - The drive shaft will remain in the cylinder block. (Do not lose the locating dowel in the cylinder block).
8) Clean all parts before replacing the new oil pump
9) Install in reverse order

NOTE: If it is necessary to remove the oil pump drive shaft, the cylinder block will have to be disassembled. Also it is a good idea to coat all parts with oil prior to installing the new pump.

Scavenger Oil Pump

1) Remove the engine from the frame
2) Remove the engine read cover
3) Remove the clutch outer housing
4) Remove the bolts holding the oil pump to the cylinder block and remove the pump

NOTE: Both of these pumps can be rebuilt with fairly easy and it's considerably less expensive to do so.

Removal & Installation 2.2L Engine To Remove:

1. Disconnect the battery ground cable.
2. If equipped with an automatic transmission, remove the exhaust manifold..
3. Drain the cooling system.
4. Raise and safely support the vehicle.
5. Remove or disconnect the following:
   • Right front wheel and tire assembly.
   • Right front fender liner.
     
     
   • Access plate on the water pump sprocket from the timing cover.
6. Install J 43651 water pump sprocket holder or equivalent to the water pump sprocket.
7. Use the access plate bolts to attach J43651 to the engine front cover.
8. Remove or disconnect the following:
   • Bolts that secure the sprocket to the water pump.
   • Bolt that secures the engine block to the water pump.
   • Bolt that secures the engine front cover to the water pump.
   • Feed pipe that joins the thermostat housing to the water pump.
     
     
   • 2 Bolts that secure the water pump to the engine block.
   • Water pump.

To Install:

1. Use a threaded stud in the hub to align the water pump sprocket.
2. Install or connect the following:
   • Water pump.
   • 2 bolts that secure the water pump to the engine block.
   • Feed pipe that joins the thermostat housing to the water pump.
   • Front cover bolt and the bolt that secures the engine block to the water pump. Tighten the bolts to 15 ft lbs (20 Nm).
   • 2 of the bolts that secure the water pump sprocket to the water pump.
3. Remove the threaded stud.
4. Install the last bolt.
   • Tighten the bolts to 89 in lbs (10 Nm).
5. Remove J 43651.
6. Install the access plate on the water pump sprocket to the timing cover.
7. Install the access plate bolts.
   • Tighten the bolts to 18 in lbs (10 Nm).
8. Install the front fender liner.
9. Install the right front tire and wheel.
10. If equipped with an automatic transmission, install the exhaust manifold.
11. Fill the cooling system.
12. Connect the battery ground cable.

2.4L Engine To Remove:
Water pump 2.4L

1. Disconnect the negative battery cable
2. Drain the engine coolant.
3. Remove the exhaust manifold.
4. Remove the coolant intake pipe as follows:
   1. Remove the coolant inlet pipe bolts.
   2. Remove the wheel and tire assembly.
   3. Remove the engine splash shield.
   4. Remove the bolts from the transaxle-to-engine block brace and remove the brace.
   5. Remove the radiator hose from the coolant inlet pipe.
   6. Remove the coolant inlet pipe to oil pan bolt.
   7. Remove the coolant inlet pipe, thermostat and seal.
5. Lower the vehicle.
6. Disconnect the heater hose quick connect from the heater outlet pipe.
7. Remove the front timing chain cover and the chain tensioner.
8. Unfasten the water pump-to-cylinder block bolts.
9. Remove the water pump-to-timing chain housing nuts.
10. Remove the water pump and cover mounting bolts and nuts.
11. Remove the water pump and cover as an assembly. Separate the two pieces after removal.
12. Clean the mating surfaces.

To Install:

1. Install the water pump cover to the water pump assembly.
2. Install and hand tighten the pump cover mounting bolts.
3. Install water pump cover assembly.
4. Install and hand tighten the cover-to-block mounting bolts.
5. Install and hand tighten the water pump-to-timing chain housing nuts.
   • Tighten the water pump-to-timing chain housing mounting nuts to 19 ft lb (26 Nm).
   • Tighten the water pump cover-to-water pump mounting bolts to 124 in lb (14 Nm).
   • Tighten the water pump cover-to-engine block bolts starting with the bottom bolt first to 19 ft lb (26 Nm).
6. Install the heater hose to the water pump pipe.
7. Using new gaskets, install the exhaust manifold.
8. Install the oil level indicator and tube.
9. Connect the brake vacuum tube to the cam housing.
10. Raise and safely support the vehicle.
11. Install the catalytic converter.
12. Install the coolant inlet pipe.
    • Tighten the inlet pipe-to-oil pan bolt to 19 ft lb (26 Nm). Tighten the coolant inlet pipe bolt to 124 in lb (14 Nm).
13. Install the timing chain and tensioner.
14. Lower the vehicle.
15. Connect the oxygen sensor.
16. Fill cooling system and check the system for leaks.

3.4L Engine To Remove:

1. Disconnect the battery ground cable.
2. Drain the cooling system.
3. Loosen the water pump pulley bolts.
4. Remove or disconnect the following:
   • Drive belt.
   • Water pump pulley bolts and pulley.
   • Water pump bolts, pump and gasket.
   • Clean the water pump mating surfaces.

To Install:

1. Install or connect the following:
   • Water pump gasket and pump.
   • Water pump bolts.
     1. Tighten the water pump bolts to 89 in lbs (10 Nm).
   • Water pump pulley and bolt until snug.
   • Drive belt.
2. Tighten the water pump pulley bolts to 18 ft. lbs (25 Nm).
3. Fill the cooling system.
4. Check for leaks.
5. Connect the battery ground cable.

4.8L, 5.3L and 6.0L Engines

1. • Timing mark alignment-4.8L, 5.3L & 6.0L
     
     
   • Locate the camshaft sprocket alignment mark in the 6 o'clock position and install the camshaft sprocket and timing chain
   • Camshaft sprocket bolts and tighten the camshaft sprocket bolts;
     1. Torque to: 26 ft. lbs. (35 Nm)
   • Oil pump
   NOTE: Do not lubricate the oil seal sealing surface.
   
2. Lubricate the outer edge of the oil seal with clean engine oil.
3. Lubricate the front cover oil seal bore with clean engine oil.
4. Install the crankshaft front oil seal with a suitable seal installer. NOTE: Do not apply any type sealant to the front cover gasket (unless specified). Special tools are used to properly align the engine front cover at the oil pan surface and to center the crankshaft front oil seal.
   
5. Install the front cover gasket, cover, and bolts onto the engine.
6. Install the front cover-to-oil pan bolts and do not overtighten.
7. Tighten the cover bolts finger tight and do not overtighten. J41480 installation-4.8L, 5.3L & 6.0L
   
   
8. Start the J41480 or other suitable tool to front cover bolts but don’t tighten the bolts yet. NOTE: Align the tapered legs of the tool with the machined alignment surfaces on the front cover.
   Seal alignment tool installation-4.8L, 5.3L & 6.0L
   
   
9. Install tool J41476 or other suitable tool.
10. Install the crankshaft balancer bolt and tighten the crankshaft balancer bolt by hand until snug but do not overtighten.
11. Tighten the J41480 bolts and front cover bolts;
    • Torque to: 18 ft. lbs. (25 Nm).
12. Remove the tools. NOTE: Place a straight edge across the engine block and front cover oil pan sealing surfaces. Avoid contact with the portion of the gasket that protrudes into the oil pan surface. Insert a feeler gauge between the front cover and the straight edge tool. The cover must be flush with the oil pan surface or no more than 0.5 mm (0.02 in) below flush. If the front cover-to-engine block oil pan surface alignment is not within specifications, repeat the cover alignment procedure. If the correct front cover-to-engine block alignment cannot be obtained, replace the front cover.
    
13. Snug the oil pan-to-cover bolts in order to position the cover at the pan rail.
14. Tighten the oil pan-to-front cover bolts;
    • Torque to: 18 ft. lbs. (25 Nm).
15. Tighten the front cover bolts;
    • Torque to: 18 ft. lbs. (25 Nm).
16. Install the crankshaft balancer and bolt (See: Crankshaft Damper).
17. Install the water pump (See: Water Pump).
18. Fill the engine to the proper level with oil.
19. Fill the engine to the proper level with coolant.
20. Test drive the vehicle to confirm the repairs.

6.6L Engine To Remove:
NOTE: The 6.6L engine uses gears in place of a timing chain. For removal and installation, please see the Camshaft and Lifters procedure. This procedure covers the removal of the front cover and seal.

1. Before servicing the vehicle refer to the precautions at the beginning of this section.
2. Remove the upper intake manifold sight shield as follows:
   • Remove the retaining bolt in the front of the shield
   • Lift up on the front of the shield, then lift the shield off the rear bracket
3. Drain the cooling system.
4. Remove or disconnect the following:
   • Negative battery cables
   • Right front wheel
   • Right front fender splash shield
   • Upper fan shroud
   • Fan clutch (See: Engine Fan and Clutch)
   • Drive belt
   • Oil dipstick tube
   • Thermostat housing crossover
   • Crankshaft damper (See: Crankshaft Damper)
   • Crankshaft front oil seal
   • Water pump (See: Water Pump)
   • Camshaft sensor electrical connector
   • Camshaft sensor bolt and sensor
   • Crankshaft Position (CKP) sensor connector, bolt and sensor
   • CKP sensor spacer bolts and spacer
   • 5 bolts securing the upper oil pan to the front cover
   • Bracket bolts and the bracket for the turbocharger outlet coolant pipe
   • Engine front cover bolts
   • Use a suitable seal cutter to separate the front cover from the cylinder block and upper oil pan NOTE: Do not bend the turbocharger outlet pipe.
     
   • O-ring from the front cover Engine front cover-6.6L engine
     
     
   • Oil pressure relief valve from the front cover

To Install:

1. Clean and inspect all sealing surfaces.
2. Install or connect the following:
   • Oil pressure relief valve with a new O-ring and tighten the valve
     1. Torque to: 30 ft. lbs. (41 Nm)
3. Apply a 1/8 in. (2-3mm) wide to 1/16 in. (0.5-1.5mm) high bead of sealant to the front cover sealing surfaces to the engine block and oil pan.
4. Install or connect the following:
   • New front cover O-ring after lubricating it with engine oil
   • Front cover and bolts and tighten the front cover bolts
     1. Torque to: 15 ft. lbs. (20 Nm)
   • Upper oil pan-to-front cover bolts and tighten the bolts
     1. Torque to: 15 ft. lbs. (20 Nm)
   • Turbocharger coolant outlet pipe bracket and bolts and tighten the bolts
     1. Torque to: 15 ft. lbs. (20 Nm).
   • Camshaft sensor and bolt and tighten the bolt
     1. Torque to: 80 inch lbs. (9 Nm)
   • Camshaft sensor connector NOTE: The CKP sensor spacers are machined with different timing positions. If you have to replace a spacer, make sure it has the same part number.
     
   • CKP sensor spacer and spacer bolts and tighten the bolts
     1. Torque to: 89 inch lbs. (10 Nm)
   • CKP sensor and bolt and tighten the bolt
     1. Torque to: 89 inch lbs. (10 Nm)
   • Water pump (See: Water Pump)
   • Crankshaft front oil seal
   • Crankshaft damper (See: Crankshaft Damper)
   • Thermostat housing crossover
   • Oil fill tube
   • Drive belt
   • Upper fan shroud
   • Right front fender splash shield and wheel
   • Negative battery cables
5. Refill the cooling system with the proper type and quantity of antifreeze.
6. Inspect the engine for leaks.
7. Test drive the vehicle to confirm the repairs.

Removal & Installation

2.2L Engine

1. Before servicing the vehicle, refer to the precautions section.
2. Disconnect the negative battery cable.
3. Drain the engine coolant.
4. Remove or disconnect the following:
   Exhaust manifold, if equipped with n automatic transaxle Right front wheel Splash shield Water pump sprocket access plate from the timing cover
   
   
   
   Fig. Remove the water pump sprocket access plate from the timing cover -2.2L engine
   
5. Attach Water Pump Sprocket Holding Tool J 43651to the sprocket using the access plate bolts to secure the tool to the engine front cover.
   Sprocket to water pump bolts Engine block to water pump bolt Engine front cover to water pump bolt Thermostat housing to water pump feed pipe 2 water pump to engine block bolts Water pump
   
   
   
   Fig. Water pump mounting-2.2L engine
   

To install:

1. Use a threaded stud in the water pump hub to align the hub to the water pump sprocket.
   Water pump and bolts Thermostat housing to water pump feed pipe Engine front cover bolt and engine block to water pump bolt. Tighten the bolts to 15 ft. lbs. (20 Nm) 2 of the water pump sprocket to water pump bolts
   
2. Remove the threaded stud.
   Last water pump sprocket to water pump bolt and tighten the sprocket bolts to 89 inch lbs. (10 Nm).
3. Remove the tool.
   Water pump sprocket access plate to the timing cover and tighten the bolts to 89 inch lbs. (10 Nm) Splash shield Right front wheel Exhaust manifold, if removed
4. Fill the cooling system.
5. Connect the negative battery cable.

2.4L Engine

1. Before servicing the vehicle, refer to the precautions section.
2. Disconnect the negative battery cable.
3. Drain the cooling system.
4. Remove or disconnect the following:
   WARNING Do not rotate the flex coupling more than 4 degrees or damage may occur. Oxygen Sensor (O 2 S) electrical connector Exhaust manifold heat shield Coolant inlet housing bolt through the exhaust manifold Exhaust manifold brace-to-manifold bolt Manifold-to-exhaust pipe studs Coolant inlet housing-to-water pump cover bolt Exhaust pipe from the exhaust manifold by pulling it downward Coolant inlet pipe from the oil pan Brake vacuum pipe from the camshaft housing Exhaust manifold from the cylinder head Heater hose from the heater outlet pipe Timing chain cover and tensioner Water pump cover-to-engine bolts 3 water pump-to-timing chain housing nuts Water pump and cover assembly Water pump cover from the pump
   
   
   
   Fig. Exploded view of the water pump mounting-2.4L engine
   

continue...

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.

Section 03-01: Engine, 4.6L (4V) 1997 Continental Workshop Manual IN-VEHICLE SERVICE Oil Pan/Oil Pump Screen Cover and Tube Removal

1. Turn rear suspension leveler compressor switch (5K761) off (located in luggage compartment).
   

1. Disconnect battery ground cable (14301). Refer to Section 14-01 .
   

1. Remove oil level dipstick (6750).
   

1. Raise vehicle on hoist.
   

1. Remove dual converter Y pipe (5F250). Refer to Section 09-00 .
   

1. Drain engine oil from crankcase.
   

1. Disconnect engine control sensor wiring (12A581) from the low oil level sensor connector.
   

1. Remove the power steering pressure hose retainer brackets from the engine front cover studs (two places). Position the power steering pressure hose (3A719) out of the way.
   

1. Remove 16 bolts retaining oil pan (6675) to cylinder blocks (6010) and remove oil pan and oil pan gasket (6710).
   

1. Remove two bolts retaining oil pump screen cover and tube (6622) to oil pump (6600).
   

1. Remove bolt retaining oil pump screen and cover and tube support brace to main bearing stud spacer.
   

1. Remove oil pump screen cover and tube. Discard O-ring.
   
   

Item Part Number Description 1 W701240 Bolt (16 Req'd) 2 6675 Oil Pan 3 6622 Oil Pump Screen Cover and Tube 4 6010 Cylinder Blocks 5 6710 Oil Pan Gasket A — Tighten to 20 Nm (14 Lb-Ft), then rotate 60 degrees clockwise

Installation

1. Inspect oil pump screen cover and tube and replace if necessary.
   
1. Position oil pump screen cover and tube on oil pump with a new O-ring and hand-start two bolts.
   
1. Install bolt retaining oil pump screen cover and tube to main bearing stud spacer finger-tight.
   
1. Tighten oil pump screen cover and tube-to-oil pump bolts to 8-12 Nm (71-106 lb-in). Tighten oil pump screen cover and tube to main bearing stud spacer bolt to 20-30 Nm (15-22 lb-ft).
   
1. Clean oil pan and inspect for damage.
   
1. Clean sealing surfaces of engine front cover (6019) and cylinder blocks with a clean cloth. If scraping is required, only use plastic-tipped scrapers to prevent damaging the aluminum sealing surfaces.
   
1. Position new oil pan gasket on oil pan.
   
1. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 where engine front cover meets cylinder blocks and crankshaft rear oil seal retainer meets cylinder blocks. Position oil pan on cylinder blocks and install 16 bolts. Tighten bolts in sequence to 20 Nm (14 lb-ft), then rotate an additional 60 degrees clockwise.