Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Water Pump

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REMOVAL & INSTALLATION




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.

2.2 and 2.5L Except Premier Engines

See Figures 1, 2, 3, 4 and 5

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Fig. Fig. 1: Water pump mounting screw locations-2.2L and 2.5L engines



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Fig. Fig. 2: Some water pumps may be equipped with one attaching stud-make certain to note its original location for proper installation



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Fig. Fig. 3: After removal of the water pump, remove and discard the old gasket-a new one is needed for installation



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Fig. Fig. 4: Exploded view of the body assembly and the housing-earlier models call for sealant, whereas newer models (1988-95) utilize gaskets (shown) between the assembly and housing



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Fig. Fig. 5: The 2.2L Turbo III engines utilize a coolant deflector in the engine block for increased cooling system performance

  1. Disconnect the battery negative cable.
  2.  
  3. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  4.  
  5. Drain the cooling system through the draincock, located on the bottom right-hand side of the radiator, into a large, clean catch pan.
  6.  
  7. Remove the upper radiator hose.
  8.  
  9. Remove the alternator, as described in this repair guide.
  10.  

Do not disconnect the air conditioner compressor lines during water pump removal. The compressor can be moved far enough out of the way to remove the water pump without disturbing the refrigerant-filled lines. A/C system refrigerant lines require special knowledge for servicing, refer to the A/C system cautions and warnings in this information for further information.

  1. On models with non-solid mount compressors, unbolt the air conditioning compressor brackets from the water pump. On solid mount compressors, remove the compressor-to-engine bolts. Secure the compressor out of the way. Suspend the compressor with strong cord or wire so that it will not put stress on the refrigerant lines.
  2.  
  3. Disconnect the bypass hose, heater return hose, and lower radiator hose.
  4.  
  5. Unbolt and remove the water pump assembly. On the 2.2L Turbo III engine, there is a spacer between the water pump and engine block on the lower bolt; make certain to retain this spacer for reassembly.
  6.  
  7. To disassemble the pump, perform the following:
    1. Remove the 3 bolts fastening the drive pulley to the water pump.
    2.  
    3. Remove the 9 bolts fastening the water pump body to the housing. Then, use a chisel to gently break the bond between the pump and housing.
    4.  

  8.  

To install:
  1. Assemble the water pump as follows, if necessary:
    1. Clean the gasket surfaces on the pump body and housing. Remove the O-ring gasket and discard it. Clean the O-ring groove.
    2.  
    3. Either apply RTV sealer to the sealing surface of the water pump body or use a new gasket during assembly. If using sealant, the bead should be 1 / 8 in. (3mm) in diameter and should encircle all bolt holes. Assemble the pump body to the housing, install the 9 bolts, and tighten them to 105 inch lbs. (12 Nm). Make sure the gasket material has set (as per package instructions) before actually filling the system.
    4.  
    5. Position a new O-ring in the groove, then situate the pulley on the pump. Install the 3 attaching bolts, and tighten them to 21 ft. lbs. (28 Nm).
    6.  

  2.  
  3. For 2.2L Turbo III engines, install the coolant deflector into the engine block before installing the water pump on the engine.
  4.  
  5. Position the water pump on the engine and, on 2.2L Turbo III engines, install the spacer.
  6.  
  7. Install the water pump mounting bolts finger-tight.
  8.  
  9. Tighten the top 3 water pump bolts to 21 ft. lbs. (28 Nm) and the lower bolt to 50 ft. lbs. (68 Nm).
  10.  
  11. Install the bypass, heater return and lower radiator hoses. For more information on cooling system hose servicing, refer to elsewhere in this repair guide.
  12.  
  13. Install the A/C compressor, as described elsewhere in this information.
  14.  
  15. Install the alternator. For more information, refer to elsewhere in this information.
  16.  
  17. Install the upper radiator hose and close the radiator draincock.
  18.  
  19. Lower the vehicle and remove the wheel blocks.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Fill the cooling system with a 50/50 mixture of water and antifreeze, as described elsewhere in this information.
  24.  
  25. Start the engine, allow the engine to warm up to normal operating temperature, check for coolant leaks, turn off the engine, allow the engine to cool, then refill the cooling system as needed.
  26.  

2.5L Premier Engine

See Figures 6 and 7

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Fig. Fig. 6: Front and rear view of the water pump assembly-2.5L Premier engines



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Fig. Fig. 7: Exploded view of the water pump-make certain to tighten the mounting bolts to 13 ft. lbs. (18 Nm)

The Eagle Premier model is equipped with a 2.5L engine manufactured by Jeep rather than the 2.5L except Premier engine found in all other models covered by this information.

  1. Disconnect the negative battery cable.
  2.  
  3. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  4.  
  5. Drain the cooling system through the draincock, located on the bottom right-hand side of the radiator, into a large, clean catch pan. For more information, refer elswhere in this information.
  6.  
  7. Remove the serpentine drive belt, as described elsewhere in this information, from the engine.
  8.  
  9. Disconnect the coolant hoses from the water pump. Remove the water pump pulley mounting bolts and remove the pulley.
  10.  
  11. Remove the water pump mounting bolts and remove the pump.
  12.  
  13. Clean the gasket mating surfaces.
  14.  

To install
  1. Install the water pump using a new gasket and tighten the mounting bolts to 13 ft. lbs. (18 Nm).
  2.  
  3. Install the hoses and the water pump pulley. Tighten the pulley retaining bolts to 20 ft. lbs. (27 Nm).
  4.  
  5. Install the accessory serpentine belt. For more information, refer to elsewhere in this information.
  6.  

It is important that the serpentine belt is installed correctly. If it is incorrectly routed, the water pump could be rotated in the wrong direction, causing the engine to overheat.

  1. Close the radiator draincock, lower the vehicle and remove the wheel blocks.
  2.  
  3. Fill the cooling system and connect the negative battery cable.
  4.  
  5. Start the engine and bleed the cooling system.
  6.  

2.6L Engine

See Figure 8

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Fig. Fig. 8: Exploded view of the water pump unit for 2.6L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  4.  
  5. Drain the cooling system through the draincock, located on the bottom right-hand side of the radiator, into a large, clean catch pan.
  6.  
  7. Disconnect the radiator, bypass, and heater hoses from the water pump.
  8.  
  9. Remove the 2 mounting bolts and remove the drive pulley shield.
  10.  
  11. Remove the lockscrew and the 2 pivot screws. Then, separate the pump from the drive belt and remove it from the engine.
  12.  
  13. Remove the bolts attaching the water pump housing to the pump body and separate the pump from the body.
  14.  

To install:
  1. Discard the gasket and clean the gasket surfaces. Discard the used O-ring and clean the O-ring groove.
  2.  
  3. Install a new gasket on the pump body, then position the pump assembly onto it. Install the attaching bolts and tighten them to 80 inch lbs. (9 Nm). Position a new O-ring into the appropriate groove.
  4.  
  5. Position the pump on the engine, install the drive belt, and install the pivot and locking screws finger-tight. Tension the drive belt, as described elsewhere in this information, then tighten all 3 mounting bolts to 17 ft. lbs. (23 Nm).
  6.  
  7. Install the drive pulley cover.
  8.  
  9. Install the radiator, bypass and heater hoses to the water pump, as described elswhere in this information.
  10.  
  11. Close the radiator draincock, lower the vehicle and remove the wheel blocks.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Refill the system (make sure that the thermostat is open) with 50/50 antifreeze/water mix. Recheck coolant level after vehicle has cooled.
  16.  

 
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