How to Install a Water Pump in a Dodge Caravan

Dodge Caravans don't haul heavy farm equipment, but they do carry kids and groceries on errands in stop-and-go traffic five to six days a week. This type of driving is hard on the water pump, which cools the minivan's engine. If your water pump goes out, some simple instructions will help you install a new one.

Instructions

Remove the Old Pump

1

Raise the hood and use a screwdriver to unscrew the clamp that connects the negative battery cable to the battery post. Remove the cable.

2

Elevate the Dodge Caravan with a jack, using the jack stands to shore up the jack. Place an engine support underneath the minivan, position it under the motor, according to the manufacturer's instructions.

3

Take off the radiator's cap slowly to release pressure. Locate the drain plug at the bottom of the radiator, just behind the grill. Place an empty container under the drain plug, remove the plug with an adjustable wrench and drain the radiator.

4

Mark in grease pencil on the timing belt its position in each pulley before removal. This will save time when reinstalling. If needed, replace the timing belt and skip marking the old one.

5

Disconnect or remove the parts in front of the water pump. In order, they are the right inner splash shield, accessory drive belts, right motor mount and bracket, front cover, timing belt, timing belt idler pulley, camshaft sprockets, timing belt rear cover, alternator and bracket.

Install the New Pump

6

Spread a bead of high temperature automotive sealant on the new water pump, in a position that coordinates to the o-ring groove. Position the o-ring over the sealant on the pump and hold it in place as you mount the new water pump on the side of the Dodge Caravan's engine.

7

Place the new bolts into the holes. Tighten the bolts, using the torque tightening measurements that vary by the engine. A 3.0L engine uses 20 foot pounds of torque to secure these bolts, while the 2.4L, 3.3L and 3.8L engines need 105 inch pounds torque tightening.

8

Reassemble the other engine parts in the order they came off the Dodge Caravan, tightening key components with a torque wrench to the proper torque. The water pump pulley bolts require 250 inch-lb torque. On the right mount, the frame rail bolts need 50 foot pounds, 75 foot pounds and 111 foot pounds torque for the vertical and horizontal fasteners respectively. The camshaft sprocket bolts need 75 foot pounds torque and the timing belt idler pulley bolt requires 45 foot pounds torque.

9

Reconnect the timing belt back, using your grease pencil marks as a guide. Finish reconnecting the other parts.

10

Insert the drain plug and refill the radiator with the amount and type of coolant specified in your owner's manual.

11

Release the engine support, jack and jack stands. Attach the negative battery cable to the post and tighten the screw on the clamp. Start the engine and check for leaks. Then, close the hood.