Chrysler Full-Size Vans 1989-1998 Repair Guide

Water Pump

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10

  1. Disconnect the negative battery cable.
  2.  
  3. Drain and recycle the engine coolant.
  4.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the air cleaner intake tube (if necessary).
  2.  
  3. Remove the upper radiator hose.
  4.  
  5. Remove the fan shrouds.
  6.  
  7. Remove the engine fan.
  8.  


WARNING
Do not place the viscous fan drive assembly in the horizontal position. If placed horizontally, the silicone fluid in the viscous drive could drain into its bearing assembly and contaminate the bearing lubricant.

  1. Remove the drive belt(s).
  2.  
  3. If the vehicle has V-belts:
    1. Remove the alternator.
    2.  
    3. Remove the bracket that supports the alternator, compressor or idler pulley (without A/C). The compressor will be supported by a rear mounting bracket.
    4.  
    5. Remove the air pump.
    6.  
    7. Remove the power steering pump front mounting bracket (if equipped). It is not necessary to remove the hoses. Support the power steering pump with mechanic's wire or equivalent.
    8.  

  4.  
  5. If the vehicle has a serpentine belt:
    1. Remove the water pump pulley bolts.
    2.  

  6.  
  7. Disconnect the lower radiator hose from the water pump.
  8.  
  9. Label and disconnect the heater and bypass hoses from the water pump. On later models, to ease installation, remove the pump before you remove the bypass hose.
  10.  

On some later models, it may be necessary to remove the heater hose tube; this is done by removing the bracket and twisting the tube to release. Discard the old O-ring and replace with a new one for reassembly.

  1. Remove the water pump retaining bolts, noting their location.
  2.  



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Fig. Fig. 1: Use a prybar to keep the water pump from rotating while removing its pulley bolts



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Fig. Fig. 2: After the bolts are removed from the pulley, pull it off the water pump shaft



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Fig. Fig. 3: The water pump mounting bolts are accessible after the pulley is removed



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Fig. Fig. 4: The lower radiator hose attaches to the water pump on the lower passenger side



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Fig. Fig. 5: Remove the bypass hose clamp in the same manner as the radiator hose clamps



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Fig. Fig. 6: It is easier to slide the clamp up the bypass hose and remove the hose after the water pump is loose



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Fig. Fig. 7: The heater hose tube (if equipped) is held into the water pump by an O-ring, which can be released by gently twisting the tube



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Fig. Fig. 8: After removing the retaining bolts, pull the water pump off the engine block, and place it in a safe location



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Fig. Fig. 9: Make sure all old gasket material is removed and the block surface is clean before installing the pump with a new gasket



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Fig. Fig. 10: Note the location of the water pump bolts when removing; they have different lengths and must be placed in their original locations

To install:
  1. Clean the gasket surfaces thoroughly.
  2.  
  3. Install a new gasket and position the water pump on the engine block. If necessary, guide the bypass hose on at this time.
  4.  
  5. Install the bolts, in their original locations, and tighten in a crisscross pattern to 30 ft. lbs. (40 Nm).
  6.  
  7. Install the heater hoses, and bypass tube, if necessary. Tighten the clamp on the heater hose placed on the pump before the bolts are tightened.
  8.  

On the models where the tube had to be removed, install the tube into the water pump with a new O-ring, and tighten the bracket.

  1. Install the lower radiator hose.
  2.  
  3. On models with V-belts:
    1. Install the power steering pump and bracket.
    2.  
    3. Install the air pump.
    4.  
    5. Install the bracket to the alternator and the air conditioning compressor (if equipped).
    6.  
    7. Install the alternator.
    8.  

  4.  
  5. On models with a serpentine belt:
    1. Install the water pump pulley bolts, and tighten to 20 ft. lbs. (27 Nm).
    2.  

  6.  
  7. Install the drive belt(s).
  8.  
  9. Install the viscous fan assembly.
  10.  
  11. Install the fan shrouds.
  12.  
  13. Install the upper radiator hose.
  14.  
  15. If necessary, install the air cleaner intake tube.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Fill and bleed the cooling system.
  20.  
  21. Check the cooling system for leaks.
  22.  

 
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