Mechanics

HOW TO REPLACE WATER PUMP

2002 Dodge Caravan

Engine Cooling problem
2002 Dodge Caravan 6 cyl All Wheel Drive Automatic 110000 miles

How do you replace a water pump for a 2002 Dodge Grand Caravan Sport AWD?

Thanks
Avatar
Jeffsammy
January 26, 2009.



Here are the directions for all engine sizes:

Removal & Installation

2.4L Engine

Before servicing the vehicle, refer to the Precautions Section.
Drain the cooling system.
Remove or disconnect the following:
Negative battery cable
Right inner splash shield
Accessory drive belts
Right motor mount and bracket, support the engine from below before removing the mount
Front cover
Timing belt.
Timing belt idler pulley
Camshaft sprockets
Timing belt rear cover
Alternator and bracket
Water pump
To install:

Install or connect the following:
Water pump with a new O–ring gasket. Tighten the bolts to 105 inch lbs. (12 Nm). Rotate the pump by hand to make sure it moves freely.
Timing belt rear cover
Camshaft sprockets. Tighten the bolts to 75 ft. lbs. (101 Nm).
Timing belt idler pulley. Tighten the bolt to 45 ft. lbs. (61 Nm).
Timing belt
Front cover
Alternator and bracket
Right motor mount
Accessory drive belts
Right inner splash shield
Negative battery cable
Fill the cooling system.
Start the engine and check for leaks.
3.0L Engine

Before servicing the vehicle, refer to the Precautions Section.
Drain the cooling system.
Remove or disconnect the following:
Negative battery cable
Right inner splash shield
Accessory drive belts
Right motor mount
Front cover
Timing belt.
Water pump
To install:

Install or connect the following:
Water pump. Tighten the bolts to 20 ft. lbs. (27 Nm).
Timing belt
Front cover
Right motor mount. Tighten the frame rail bolts to 50 ft. lbs. (68 Nm), the vertical fastener to 75 ft. lbs. (102 Nm) and the horizontal fastener to 111 ft. lbs. (150 Nm).
Accessory drive belts
Right inner splash shield
Negative battery cable
Fill the cooling system.
Start the engine and check for leaks.
3.3L And 3.8L Engines

Before servicing the vehicle, refer to the Precautions Section.
Drain the cooling system.
Remove or disconnect the following:NOTE
To remove the water pump it must be positioned between the pump housing and the drive hub. Refer to the accompanying illustration for further clarification.
Negative battery cable
Right inner splash shield
Accessory drive belt
Water pump pulley bolts
Water pump with the pulley loosely positioned between the hub and pump body
The water pump must be positioned between the pump housing and the drive hub so it can be removed—3.3L and 3.8L engines
To install:

Install or connect the following:
New seal into the water pump housing groove
Water pump with the pulley loosely positioned between the hub and pump body. Tighten the bolts to 105 inch lbs. (12 Nm).
Water pump pulley and tighten the bolts to 250 inch lbs. (28 Nm). Rotate the pump by hand to make sure it moves freely.
Accessory drive belt
Right inner splash shield
Negative battery cable
Fill the cooling system.
Start the engine and check for leaks.

If you need to review the precautions, go to:

http://www.2carpros.com/articles/mitchell1eautorepair-car-repair-manuals

I hope this helps. Let me know if you have other questions.

Joe