Tools you'll likely need:
* Socket set and wrenches: Various sizes will be needed, including metric and possibly SAE.
* Ratchet and extensions: For reaching tight spots.
* Torque wrench: Essential for tightening bolts to the correct specifications (found in your repair manual).
* Pliers: Needlenose and regular.
* Screwdrivers: Phillips and flathead.
* Drain pan: To catch coolant.
* New water pump: Make sure you get the correct one for your engine.
* New gasket and/or seal: These are crucial to prevent leaks.
* Coolant: The correct type for your Aerostar.
* Jack and jack stands: For safe vehicle support.
* Wrench for serpentine belt tensioner: This is usually a special tool, but sometimes you can improvise with a breaker bar and a suitable point to push/pull the tensioner.
General Steps (Consult your repair manual for precise details):
1. Safety First: Disconnect the negative battery terminal. Allow the engine to cool completely before starting work. Place the vehicle on jack stands after safely raising it with a jack.
2. Drain the Coolant: Locate the radiator drain petcock and carefully drain the coolant into your drain pan. You might also need to remove a lower radiator hose.
3. Remove the Serpentine Belt: This requires loosening the tensioner pulley. Refer to your repair manual for the specific procedure, as the tensioner release mechanism varies between Aerostar models.
4. Remove Accessory Components (if necessary): Depending on your specific engine and access to the water pump, you may need to remove some components like the fan, fan shroud, or other pulleys to gain access.
5. Remove the Water Pump: This usually involves removing several bolts securing the pump to the engine block. Be careful not to damage the gasket/seal on the pump.
6. Clean the Surface: Thoroughly clean the mating surface of the engine block where the water pump sits. Remove any old gasket material.
7. Install the New Water Pump: Install the new water pump with the new gasket or seal. Tighten the bolts to the specifications outlined in your repair manual.
8. Reinstall Components: Reinstall any components you removed earlier (fan, fan shroud, pulleys, etc.).
9. Reinstall the Serpentine Belt: Ensure the belt is properly routed around all pulleys.
10. Refill Coolant: Fill the radiator and overflow reservoir with the correct type and amount of coolant.
11. Bleed the Cooling System: This is crucial to remove air pockets. Run the engine until the thermostat opens and the coolant circulates properly. Check for leaks. Add more coolant if necessary.
Important Considerations:
* Engine Type: The procedure will differ slightly depending on whether you have a 3.0L or 4.0L V6 engine. Your repair manual is essential here.
* Gasket/Seal: Use a new gasket or seal. Reusing an old one is a recipe for leaks.
* Torque Specifications: Always tighten bolts to the manufacturer's specified torque values. Using a torque wrench is crucial.
* Coolant Type: Use the correct type of coolant specified for your vehicle.
This is a simplified overview. Use a repair manual specific to your 1992 Ford Aerostar for detailed, step-by-step instructions, diagrams, and torque specifications. If you're not comfortable performing this repair yourself, take your Aerostar to a qualified mechanic. Improperly installing the water pump can lead to engine damage.
