How to Replace the Water Pump on My 1996 Mopar 3L V6

The water pump in your 3.0-liter displacement Mopar engine is responsible for keeping the coolant circulating in the cooling system. If the water pump fails, the engine can overheat, which can cause serious damage. The Mopar 3.0 was normally installed in the Dodge Caravan and Grand Caravan minivans. Changing the water pump can be accomplished in two or three hours.

Instructions

1

Loosen the lug nuts on the passenger front wheel by turning them counterclockwise with the lug wrench, without removing the lug nuts. Place the jack under the front of the frame behind the passenger front wheel. Raise the vehicle until the front wheel is off the ground. Slide the jack stand under the frame behind the jack and lower the vehicle onto the stand. Remove the lug nuts and the wheel. Place the jack with a block of wood on the jack pad under the front of the oil pan and support the engine.

2

Drain the cooling system by placing the radiator drain pan under the drain valve or plug and loosening the plug or valve by turning it counterclockwise by hand. Remove the passenger side inner splash shield by removing the bolts or screws securing it to the body. These should be turned counterclockwise with a wrench or screwdriver. Remove the engine support bracket and engine mount insulator by turning the bolts securing them counterclockwise with a wrench or socket and ratchet.

3

Release the tension on the drive belt by pivoting the belt tensioner down. Pull the belt off the crankshaft pulley, followed by the drive accessories and tensioner pulley. Mark the outside of the belt to indicate either direction of rotation or the outer edge of the belt.

4

Remove the crankshaft pulley by rotating the center bolt counterclockwise with a ratchet and socket and pulling the pulley off the crankshaft. Remove the bolts securing the two upper and one lower timing chain covers. Thread the crankshaft bolt into the crankshaft clockwise and tighten it with a wrench or ratchet and socket. Rotate the engine until the camshaft and crankshaft timing marks line up with the proper marks. Remove the crankshaft bolt.

5

Loosen the timing belt/chain tensioner by turning the pivot bolt counterclockwise. Mark the outer edge of the timing belt or the direction of rotation and remove the timing belt by sliding it off the sprockets.

6

Remove the bolts securing the water pump to the engine by turning them counterclockwise with a ratchet and socket. Grasp the water pump pulley and pull the water pump away from the engine. Clean the remnants of the old gasket using the gasket scraper.

7

Apply a thin bead of RTV Blue to the gasket mating surfaces on the new water pump and apply the gasket and O-ring to the water pump. Apply a bead of RTV Blue to the water pump gasket and connect the water tube to the back of the pump. Insert the water pump bolts and turn them clockwise by hand until finger tight. Torque the bolts to 20 foot-pounds.

8

Turn the timing belt tensioner counterclockwise full travel in the adjustment slot. Tighten the center bolt by turning it clockwise. Route the timing belt around the crankshaft, camshaft, water pump and tensioner sprockets. Loosen the tensioner bolt. Install the crankshaft sprocket flange. Turn the engine clockwise two full revolutions by turning the crankshaft bolt with a wrench or ratchet and socket. Make sure all the timing marks line up properly. Tighten the tensioner bolt by turning it clockwise with a ratchet and socket and torque this bolt to 250 inch-pounds.

9

Replace the timing belt covers. Insert the cover bolts and turn them clockwise using a ratchet and socket. Torque the bolts to 115 inch-pounds. Install the engine support bracket by turning the bolts clockwise by hand until finger tight. Torque these bolts to 35 foot-pounds. Install the engine mount isolator, holding it in place and rotating the isolator bolts clockwise by hand. Tighten them securely.

10

Remove the crankshaft pulley bolt by rotating it counterclockwise with a wrench or ratchet and socket. Install the dampener, pulley and crankshaft bolt, turning the bolt clockwise until finger tight. Torque the crankshaft bolt to 105 foot-pounds.

11

Route the drive belt around the accessories and crankshaft. Rotate the drive belt tensioner down and slide the belt over the tensioner. Release the tensioner. Replace the inner splash shield by holding it in place and turning the securing bolts/screws clockwise. Tighten these bolts with the correct tool (wrench or screwdriver).

12

Hang the wheel on the lug studs and turn the lug nuts clockwise using the lug wrench until finger tight. Lower the jack under the oil pan and reposition it under the frame. Raise the vehicle off the jack stand, remove the stand and lower the vehicle until the front wheel contacts the ground. Torque the lug nuts to 105 foot-pounds. Lower the vehicle.

13

Close the drain plug or valve by turning it clockwise by hand. Refill the cooling system with new coolant until the level reaches to just under the filler neck. Start the engine and allow it to reach operating temperature while checking for leaks. Top off the coolant as necessary to keep the level just under the filler neck. Replace the radiator cap, pressing down while turning clockwise by hand. Top off the overflow bottle to the indicated mark.