TownAndCountry 2008

Removal & Installation

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3.3L & 3.8L Engines



Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009


CAUTION
Never open, service, or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Avoid physical contact with the coolant. Wear protective clothing and eye protection. Always drain coolant into a sealable container. Clean up spills as soon as possible. Coolant should be reused unless it is contaminated or is several years old.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the accessory drive belt shield.
  6.  
  7. Remove the accessory drive belt. Refer to Engine Mechanical Components, Accessory Drive Belts, removal & installation.
  8.  
  9. Remove the water pump pulley bolts.
    NOTE
    To remove the water pump pulley, it MUST first be positioned between the water pump housing and the drive hub. The pulley can then be removed with the water pump assembly.

  10.  
  11. Rotate the pulley until the openings in the pulley align with the water pump drive hub spokes. Move the pulley inward between the pump housing and the hub.
  12.  
  13. Position the pulley to allow access to the water pump mounting bolts. Remove the water pump mounting bolts.

    Click image to see an enlarged view

    Fig. Rotate the pulley until the openings in the pulley align with the water pump drive hub spokes. Move the pulley inward between the pump housing and the hub-3.3L and 3.8L engines

  14.  
  15. Remove the water pump with the pulley loosely positioned between the hub and the pump body.
  16.  
  17. Remove and discard the seal.
  18.  
  19. Clean the seal groove and sealing surfaces on the pump and the timing chain case cover. Take care not to scratch or gouge the sealing surfaces.

    Click image to see an enlarged view

    Fig. View of water pump removal-3.3L and 3.8L engines

  20.  

To install:

  1. Ensure that the seal groove and sealing surfaces are clean and free of debris.
  2.  
  3. Install a new seal into the water pump housing groove.
    NOTE
    The water pump pulley MUST be positioned loosely between the pump housing and the drive hub BEFORE water pump installation.

  4.  
  5. Position the water pump pulley loosely between the pump housing and the drive hub.
  6.  
  7. Install the water pump and the pulley to the timing chain case cover. Tighten the water pump bolts to 105 inch lbs. (12 Nm).
  8.  
  9. Position the pulley on the water pump hub. Install the bolts and tighten to 21 ft. lbs. (28 Nm).
  10.  
  11. Rotate the pump by hand to check for freedom of movement.
  12.  
  13. Install the accessory drive belt. Refer to Engine Mechanical Components, Accessory Drive Belts, removal & installation.
  14.  
  15. Install the drive belt shield.
  16.  
  17. Fill the cooling system with the proper type and amount of fluid.
  18.  
  19. Run the engine and bleed the air from the coolant system.
  20.  
  21. Check the cooling system for leaks.
  22.  

4.0L Engine



Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009


CAUTION
Never open, service, or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Avoid physical contact with the coolant. Wear protective clothing and eye protection. Always drain coolant into a sealable container. Clean up spills as soon as possible. Coolant should be reused unless it is contaminated or is several years old.


NOTE
The water pump is driven by the timing belt.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the engine timing belt. Refer to Engine Mechanical Components, Timing Belt and Sprockets, removal & installation.
  6.  
  7. Remove the water pump mounting bolts. Note the position of the longer bolt for proper re-installation.
  8.  
  9. Remove the water pump body from the engine.

    Click image to see an enlarged view

    Fig. View of water pump removal-4.0L engine

  10.  

To install:

  1. Clean all the O-ring surfaces on the pump and cover.
  2.  
  3. Apply MOPAR® Dielectric Grease, or the equivalent silicone grease, to the O-ring to facilitate assembly. Install a new O-ring on the water pump.
  4.  
  5. Position the water pump to the engine.
  6.  
  7. Install the mounting bolts and tighten to 105 inch lbs. (12 Nm).
  8.  
  9. Install the timing belt. Refer to Engine Mechanical Components, Timing Belt and Sprockets, removal & installation.
  10.  
  11. Fill the cooling system with the proper type and amount of fluid.
  12.  
  13. Run the engine and bleed the air from the coolant system.
  14.  
  15. Check the cooling system for leaks.
  16.  

 
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