Mechanics

DODGE CARAVAN ENGINE PROBLEM

1999 Dodge Caravan • 88 miles

Whrere and how water pump to replace in 4 cylinder engine
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December 8, 2012.



REMOVAL

Disconnect negative cable from battery.
Raise vehicle on a hoist. Remove right inner splash shield.
Remove accessory drive belts.
Drain cooling system.
Support engine from the bottom and remove right engine mount.
Remove right engine mount bracket.
Remove timing belt.
Remove timing belt idler pulley.
Hold camshaft sprocket with Special tool C-4687 and adapter C-4687-1 while removing bolt. Remove both cam sprockets.
Remove rear timing belt cover.

Water Pump-2.4L Engine

Remove water pump attaching screws to engine.

INSTALLATION

Water Pump Body

Install new O-ring gasket in water pump body O-ring groove.

CAUTION: Make sure O-ring is properly seated in water pump groove before tightening screws. An improperly located O-ring may cause damage to the O-ring and cause a coolant leak.

Assemble pump body to block and tighten screws to 12 Nm (105 inch lbs.). Pressurize cooling system to 15 psi with pressure tester and check water pump shaft seal and O-ring for leaks.
Rotate pump by hand to check for freedom of movement.
Install rear timing belt cover.
Install camshaft sprockets and torque bolts to 101 Nm (75 ft. Lbs.).
Install timing belt idler pulley and torque mounting bolt to 61 Nm (45 ft. Lbs.).
Install timing belt.
Install right engine mount bracket and engine mount.
Fill cooling system.
Install accessory drive belts.
Lower vehicle and connect battery cable.