How to Install a Water Pump in Dodge Cars

Installing a new water pump into a Dodge car is a do-it-yourself job, if you have the right tools. You'll also need plenty of space in which to work and lay out parts and a moderate amount of mechanical knowledge. By following a few simple instructions, you can install a new water pump and save yourself some money instead of taking it to a shop for repair.

Under The Hood:

• How to Install a Water Pump in a Dodge Caravan
• How to Install a Water Pump in a Dodge Intrepid
• How to Install a Water Pump in a Dodge Durango
• How to Install a Water Pump in a Dodge Ram

 How to Install a Water Pump in a Dodge Caravan

Remove the Old Pump

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

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.

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.

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.

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

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.

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.

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.

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

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

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.

 How to Install a Water Pump in a Dodge Intrepid

Prepare the Dodge Intrepid

Lay out a drop cloth underneath the Dodge Intrepid to protect the floor from coolant spills. Designate an area to lay out each part alongside its bolts and connecting hoses and wires. Use a drop cloth here as well, some of the parts will have traces of grease and coolant.

Disconnect the negative battery cable, using a screwdriver to unscrew the clamp that secures the cable to the negative (-) post. Pull the cable away from the battery post.

Use a jack to elevate the Dodge Intrepid and jack stands to shore up the jack. Release the pressure in the radiator by removing the cap. Take out the drain plug located underneath the radiator. Catch the coolant in a resealable container

Use a grease pencil to mark 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.

Remove the Damaged Pump

Locate the water pump on the Dodge Intrepid. It's mounted on the front of the engine block and connected to the radiator and various other parts through a series of hoses. It's rotated by the timing belt. Study these parts, as you'll have to remove them.

Disconnect or remove the parts in front of the water pump, using an adjustable wrench. In the most common Dodge Intrepid engine--the 2.7L--you'll find, in order: the upper radiator crossmember, fan module, accessory drive belts, crankshaft damper, timing cover, timing chain and guide wires.

Unbolt the water pump from the engine block, using an adjustable wrench. You may have to use a chisel to gently break the seal between the mount and the pump. Discard both the pump and the bolts.

Clean off the mounting area with a shop rag.

Install the New Pump

Inspect the new water pump to ensure it's identical to the old pump and free of any metal splinters or debris.

Arrange the new water pump on the mount. You won't need sealant for the o-ring on a Dodge Intrepid. Hold the water pump and o-ring in place as you secure it with the new bolts. Tighten them with a torque wrench to 105 inch pounds torque in any order.

Install the timing belt and wires, using the grease pencil marks to guide you in installation. Install the rest of the parts in the order removed. The camshaft must be reconnected with a torque wrench at 125 foot pounds torque.

Replace the radiator's drain plug and refill the radiator with the amount and type of coolant specified in your owner's manual. Release the jack and jack stands.

Attach the negative battery cable to the post and tighten the screw on the clamp. Crank the Dodge Intrepid's engine and check for leaks. Then, close the hood.

 How to Install a Water Pump in a Dodge Durango

Extract the Old Pump

Use a jack to raise the SUV. Secure it with automotive jack stands.

Unhook the negative battery cable, using a screwdriver to unscrew the clamp that secures the cable to the negative (-) post. Pull the cable away from the battery post.

Remove 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 and drain the radiator. Dispose of the used fluid safely, as it's toxic.

Locate the water pump, commonly mounted on the front of the engine block on the Dodge Durango. Remove all the engine components in front of the water pump in the following order: fan, fan shroud, drive belt, fan clutch, hoses connected to the water pump and other components like the radiator. Lay the fan clutch assembly vertically to avoid silicon spill.

Unbolt the water pump from the engine using the adjustable wrench. Take it off. Remove any debris from the mount with a shop rag.

Install New Pump

Position the new water pump on the mount. You won't need sealant or a gasket for a Dodge Durango. Hold the water pump in place as you secure it with eight new bolts. Tighten them to 40 foot pounds torque (18 foot pounds torque for 5.7L engines) in any order.

Install the rest of the components in the order you removed them. Replace the radiator's drain plug and refill the radiator with the amount and type of coolant specified in your owner's manual.

Remove the jack and jack stands. Start the Dodge Durango's engine and check for leaks. Fasten the negative battery cable to the post and tighten the screw on the clamp. Then, close the hood and clean up any spilled coolant.

 How to Install a Water Pump in a Dodge Ram

Prepare the Truck

Arrange a drop cloth underneath the Dodge Ram to protect the floor from coolant spills. Designate an area to lay out each part alongside its bolts and connecting hoses and wires. Some of the parts will have traces of grease and coolant, so you may need a drop cloth here, as well.

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

Raise the truck with a jack. Secure it with automotive jack stands. Alternately, use tire ramps for added convenience.

Untwist 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.

Taking Out the Old Pump

Use the adjustable wrench to undo the bolts securing the Dodge Ram's wiring harness retainer.

Loosen the seven bolts on the water pump pulley to get to and remove the accessory drive belt. Don't bend the belt in any way, as it may cause damage.

Unbolt the four bolts mounting the water pump to the engine with an adjustable wrench. Undo the bolts in any order. Remove the water pump and gasket from the engine.

Clean off the mounting area with a shop rag. Scrape away gasket pieces that may still adhere to the engine.

Connect the New Pump

Position the new gasket onto the water pump. Place a bead of high temperature automotive sealant around the area where you removed the old pump and hold the gasket in place on the new water pump, as you mount the entire assembly on top of the sealant.

Affix new bolts into the holes in the Dodge Ram's water pump in any order, using a torque wrench while the sealant is still wet to obtain a better hold. Tighten to 18 foot pounds of torque (40 foot pounds for the 3.7L and 4.7L engines and 20 foot pounds for the 3.9L, 5.2L and 5.9L engines).

Reassemble the rest of the parts in the order you took them off the Dodge Ram. Replace any parts that appear worn or damaged. Put the drain plug back in the radiator and refill with coolant. Remove the jack and jack stands, or drive the truck off the tire ramps.

Reconnect the negative battery cable to the post and tighten the screw on the clamp. Start the Dodge Ram's engine and check for leaks. Then, close the hood and take the truck for a test drive.