Chrysler Caravan/Voyager/Town n Country 1984-1995

Water Pump

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REMOVAL & INSTALLATION



2.2L and 2.5L Engines

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Water pump assembly installation-2.2L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.Jack up the front of the vehicle, support on jackstands and remove the lower splash shield to access the water pump and drive belts.

  1. Remove the drive belts. (Refer to General Information & Maintenance ).
  2.  
  3. Remove the upper radiator hose.
  4.  
  5. Without discharging the system, remove the air conditioning compressor from the engine mount and set to one side. If necessary remove the compressor mount (4 bolts) to gain access to the water pump retaining bolts.
  6.  
  7. Remove the alternator and move to one side.
  8.  
  9. Disconnect the lower radiator hose and heater hose.
  10.  
  11. Remove (3) upper screws and (1) lower screw retaining the water pump to the engine, then remove pump assembly.
  12.  

To install:
  1. Position the replacement pump against the engine and install mounting screws. Tighten the (3) upper screws to 21 ft. lbs. (28 Nm) and lower screw to 50 ft. lbs. (68 Nm).
  2.  
  3. Install heater hose and lower radiator hose. Tighten the clamps to 16 inch lbs. (2 Nm).
  4.  
  5. Install air conditioning compressor and alternator.
  6.  
  7. Install the drive belts and adjust to specification.
  8.  
  9. Fill the cooling system.
  10.  
  11. Connect the negative battery cable.
  12.  

2.6L Engine

See Figure 2



Click image to see an enlarged view

Fig. Fig. 2: Water pump mounting-2.6L engines

  1. Drain the cooling system.
  2.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the radiator hose, by-pass hose and heater hose from the water pump.
  2.  
  3. Remove the drive pulley shield.
  4.  
  5. Remove the locking screw and pivot screws.
  6.  
  7. Remove the drive belt and water pump from the engine.
  8.  
  9. Install a new O-ring gasket in O-ring groove of pump body assembly to cylinder block.
  10.  
  11. Position the water pump assembly against the engine and install pivot screws and locking screw finger-tight.
  12.  
  13. Install the water pump drive belt and adjust to specification. New belts should have 0.31 in. (8mm) deflection, used belts should have 0.35 in. (9mm) deflection.
  14.  
  15. Install drive belt pulley cover.
  16.  
  17. Install the radiator hose, by-pass hose and heater hose.
  18.  
  19. Fill the cooling system.
  20.  

3.0L Engine

See Figure 3



Click image to see an enlarged view

Fig. Fig. 3: Water pump mounting-2.6L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the drive belts.
  4.  
  5. Drain the cooling system.
  6.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the timing case cover and timing belt. Refer to Timing Belt Covers and Timing Belt Removal procedures.
  2.  
  3. Remove the pump assembly mounting bolts.
  4.  
  5. Separate the pump assembly from water pipe and remove.
  6.  
  7. Clean gasket and O-ring mounting surfaces.
  8.  
  9. Install a new O-ring on water pipe and lubricate with water.
  10.  
  11. Install a new gasket on pump body.
  12.  
  13. Press the water pump assembly into water pipe.
  14.  
  15. Install pump mounting bolts and tighten to 27 Nm (20 ft. lbs.).
  16.  
  17. Install timing belt and cover. Refer to Timing Belt procedures.
  18.  
  19. Install drive belts.
  20.  
  21. Fill the cooling system.
  22.  

3.3L and 3.8L Engines

See Figure 4



Click image to see an enlarged view

Fig. Fig. 4: Water pump-3.3L and 3.8L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the serpentine belt.
  6.  
  7. Raise the vehicle and support safely. Remove the right front tire and wheel assembly and lower fender shield.
  8.  
  9. Remove the water pump pulley.
  10.  
  11. Remove the 5 mounting screws and remove the pump from the engine.
  12.  
  13. Discard the O-ring.
  14.  

To install:
  1. Using a new O-ring, install the pump to the engine. Tighten the mounting bolts to 21 ft. lbs. (30 Nm).
  2.  
  3. Install the water pump pulley.
  4.  
  5. Install the fender shield and tire and wheel assembly. Lower the vehicle.
  6.  
  7. Install the serpentine belt.
  8.  
  9. Remove the engine temperature sending unit. Fill the radiator with coolant until the coolant comes out the sending unit hole. Install the sending unit and continue to fill the radiator.
  10.  
  11. Connect the negative battery cable, run the vehicle until the thermostat opens, fill the radiator completely and check for leaks.
  12.  
  13. Once the vehicle has cooled, recheck the coolant level.
  14.  

OVERHAUL



2.2L and 2.5L Engines

See Figure 5



Click image to see an enlarged view

Fig. Fig. 5: Disassembled view of the water pump housing and body-2.2L engines

  1. Remove the 3 screws holding the pulley to the water pump.
  2.  
  3. Remove the 9 screws holding the water pump to the body. Because of the gasket seal a chisel is required to separate the pump from the body.
  4.  
  5. Clean the gasket surfaces on the pump and the body.
  6.  
  7. Remove and discard the O-ring gasket and clean the O-ring groove.
  8.  

To assemble:

The body assembly, housing and impact nipple are serviced as separate components. On vehicles equipped with a carbureted engine, housing replacement is required. Install a new impact nipple.

  1. Apply a sealer to the circumference of the new nipple and with a light mallet tap the nipple into the housing.
  2.  
  3. Apply RTV sealant to the body. Assemble the pump to the body and tighten the screws to 105 inch lbs. (12 Nm) and allow the sealant to set before filling and pressurizing the system.
  4.  
  5. Place a new O-ring in the groove.
  6.  
  7. Position the water pump pulley to the water pump and tighten the 3 retaining screws to 105 inch lbs. (12 Nm).
  8.  

 
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