Caravan, Grand Voyager, Town and Country, Voyager, 2000-2004

Removal & Installation

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2.4L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Right inner splash shield
     
    Accessory drive belts
     
    Right motor mount and bracket, support the engine from below before removing the mount
     
    Front cover
     
    Timing belt.
     
    Timing belt idler pulley
     
    Camshaft sprockets
     
    Timing belt rear cover
     
    Alternator and bracket
     
    Water pump
     

  6.  

To install:

  1. Install or connect the following:

    Water pump with a new O-ring gasket. Tighten the bolts to 105 inch lbs. (12 Nm). Rotate the pump by hand to make sure it moves freely.
     
    Timing belt rear cover
     
    Camshaft sprockets. Tighten the bolts to 75 ft. lbs. (101 Nm).
     
    Timing belt idler pulley. Tighten the bolt to 45 ft. lbs. (61 Nm).
     
    Timing belt
     
    Front cover
     
    Alternator and bracket
     
    Right motor mount
     
    Accessory drive belts
     
    Right inner splash shield
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

3.0L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Right inner splash shield
     
    Accessory drive belts
     
    Right motor mount
     
    Front cover
     
    Timing belt.
     
    Water pump
     

  6.  

To install:

  1. Install or connect the following:

    Water pump. Tighten the bolts to 20 ft. lbs. (27 Nm).
     
    Timing belt
     
    Front cover
     
    Right motor mount. Tighten the frame rail bolts to 50 ft. lbs. (68 Nm), the vertical fastener to 75 ft. lbs. (102 Nm) and the horizontal fastener to 111 ft. lbs. (150 Nm).
     
    Accessory drive belts
     
    Right inner splash shield
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

3.3L & 3.8L Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    To remove the water pump it must be positioned between the pump housing and the drive hub. Refer to the accompanying illustration for further clarification.



    Negative battery cable
     
    Right inner splash shield
     
    Accessory drive belt
     
    Water pump pulley bolts
     



    Water pump with the pulley loosely positioned between the hub and pump body

    Click image to see an enlarged view

    Fig. The water pump must be positioned between the pump housing and the drive hub so it can be removed-3.3L and 3.8L engines

     

  6.  

To install:

  1. Install or connect the following:

    New seal into the water pump housing groove
     
    Water pump with the pulley loosely positioned between the hub and pump body. Tighten the bolts to 105 inch lbs. (12 Nm).
     
    Water pump pulley and tighten the bolts to 250 inch lbs. (28 Nm). Rotate the pump by hand to make sure it moves freely.
     
    Accessory drive belt
     
    Right inner splash shield
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

 
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