Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSFORD1991AEROSTAR 2WD V6-183 3.0LREPAIR AND DIAGNOSISENGINE, COOLING AND EXHAUSTENGINEWATER PUMPSERVICE AND REPAIRINSTALLATION
1991 Ford Aerostar 2WD V6-183 3.0L
Installation
1991 Ford Aerostar 2WD V6-183 3.0LSECTION Installation
INSTALLATION
Water Pump Fastener Chart:
NOTE: Lightly oil all bolt and stud threads before installation except those requiring special sealant.
1. Clean gasket surface on timing cover and water pump carefully. (Aluminum gouges easily.)
2. Position a new gasket on water pump sealing surface using Gasket and Trim Adhesive D7AZ-19B508-AA (ESR-M11P17-A) (or equivalent) to hold gasket in position.
Water Pump:
3. Install water pump on timing cover and hand start 11 attaching bolts. Tighten water pump bolts to following torque:
a. 8 x 1.25 mm to 25 Nm (19 ft lb).
b. 6 x 1.25 mm to 10 Nm (7 ft lb).
4. Install lower radiator hose and heater hose to pump.
5. Install water pump pulley assembly and hand tighten four attaching bolts.
6. Install alternator adjusting arm and brace.
7. Install both accessory drive belts.
8. Torque pulley bolts to 25 Nm (19 ft lb).
9. Install cooling fan.
10. Fill and bleed cooling system with proper coolant mixture.
11. Connect negative battery terminal.
12. Run engine and check for coolant leaks.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.