Engine Cooling System - Mechanical Dodge Grand Caravan IV

DIAGNOSIS AND TESTING - ENGINE COOLING SYSTEM

Establish what driving condition caused the cooling system complaint. The problem may be caused by an abnormal load on the system such as the following: prolonged idle, very high ambient temperature, slight tail wind at idle, slow traffic speed, traffic jam, high speed, steep grade.

DRIVING TECHNIQUES

To avoid overheating the cooling system

1. Idle with A/C off when temperature gauge is at end of normal range.
2. Do not increase engine speed for more air flow and coolant flow because the electric motor fan systems are not responsive to engine RPM. The added cooling from higher coolant flow rate is more than offset by increased heat rejection (engine heat added to coolant).

TRAILER TOWING

Consult the owner's manual under Trailer Towing and do not exceed specified limits.

VISUAL INSPECTION

If the cooling system problem is not caused by a driving condition, perform a visual inspection to determine if there was a recent service or accident repair, including the following

1. Loose/damaged water pump drive belt
2. Incorrect cooling system refilling (trapped air or low level)
3. Brakes possibly dragging
4. Damaged hoses
5. Loose/damaged hose clamps
6. Damaged/incorrect engine thermostat
7. Damaged cooling fan motor, fan blade and fan shroud
8. Damaged head gasket
9. Damaged water pump
10. Damaged radiator
11. Damaged coolant recovery system
12. Damaged heater core
13. Open/shorted electrical circuits

If the visual inspection reveals none of the above as cause for a cooling system complaint, refer to the following diagnostic charts.

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Refer to (Scheme 10) when using the TEMPERATURE GAUGE INDICATION DIAGNOSIS CHART.

Scheme 9

Scheme 10

CLEANING

Drain cooling system and refill with clean water. Run engine with radiator cap installed until upper radiator hose is hot. Stop engine and drain water from system. If water is dirty; fill, run, and drain system again, until water runs clear. Refill cooling system with a 50/50 mixture of the recommended ethylene glycol and distilled water.

INSPECTION

After performing a cleaning/flush procedure, inspect all hoses, clamps and connections for deterioration and leaks. Inspect radiator and heater core for leaks.

DESCRIPTION - ENGINE COOLANT

The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air.

The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol base coolant with hybrid organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of - 37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution.

The green coolant MUST NOT BE MIXED with the orange or magenta coolants. When replacing coolant the complete system flush must be performed before using the replacement coolant.

DIAGNOSIS AND TESTING - COOLANT CONCENTRATION TESTING

Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of - 37°C (-34°F) to - 46°C (-50°F). The use of a hydrometer or a refractometer can be used to test coolant concentration.

A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol).

A refractometer (Special Tool 8286)(Refer to SPECIAL TOOLS ) will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid.

Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended.

STANDARD PROCEDURE - COOLANT SERVICE

For engine coolant recommended service schedule, (Refer to MAINTENANCE SCHEDULES - DESCRIPTION ).

DESCRIPTION

The coolant recovery/reserve system container is mounted in the engine compartment (Scheme 11) The container is made of plastic.

OPERATION

The coolant recovery system works with the radiator pressure cap to use thermal expansion and contraction of the coolant to keep the coolant free of trapped air. Provides a convenient and safe method for checking coolant level and adjusting level at atmospheric pressure without removing the radiator pressure cap. It also provides some reserve coolant to cover deaeration, evaporation, or boiling losses.

DIAGNOSIS AND TESTING - COOLANT RECOVERY SYSTEM

The cooling system is closed and designed to maintain coolant level to the top of the radiator.

1. With the engine off and cooling system not under pressure, drain several ounces of coolant from the radiator draincock while observing the coolant recovery container. Coolant level in the container should drop.
2. Remove the radiator pressure cap. The coolant level should be full to the top radiator neck. If not, and the coolant level in the container is at or above the MIN mark, there is an air leak in the coolant recovery system.
3. Check hose and hose connections to the container, radiator filler neck or the pressure cap seal to the radiator filler neck for leaks.

Scheme 11

1. Raise the vehicle on hoist.
2. Remove the lower attaching screws (Scheme 11)
3. Lower the vehicle.
4. Remove the upper attaching screw (Scheme 11)
5. Disconnect recovery hose from container (Scheme 11)
6. Remove the recovery container.

INSTALLATION

1. Connect the recovery hose to container (Scheme 11)
2. Position the recovery container on the frame rail (Scheme 11)
3. Install the upper attaching screw and tighten to 7 N-m (60 in. lbs.) (Scheme 11)
4. Raise the vehicle on hoist.
5. Install the lower attaching screws and tighten to 8.5 N-m (75 in. lbs.) (Scheme 11)
6. Lower the vehicle.
7. Add coolant to container as necessary. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).

The engine block heater is available as an optional accessory on all models. The heater is operated by ordinary house current (110 Volt A.C.) through a power cord located behind the radiator grille. This provides easier engine starting and faster warm-up when vehicle is operated in areas having extremely low temperatures. The heater is mounted in a core hole (in place of a core hole plug) in the engine block, with the heating element immersed in coolant.

The block heater element is submerged in the cooling system's coolant. When electrical power (110 volt A.C.) is applied to the element, it creates heat. This heat is transferred to the engine coolant. This provides easier engine starting and faster warm-up when vehicle is operated in areas having extremely low temperatures.

DIAGNOSIS AND TESTING - ENGINE BLOCK HEATER TESTING

If unit does not operate, trouble can be in either the power cord or the heater element. Test power cord for continuity with a 110-volt voltmeter or 110-volt test light; test heater element continuity with an ohmmeter or 12-volt test light.

REMOVAL

1. Drain coolant from radiator and cylinder block. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).
2. Disconnect the power cord plug from heater.
3. Loosen screw in center of heater. Remove the heater assembly.

1. Clean block core hole and heater seat.
2. Insert heater assembly with element loop positioned upward.
3. With heater seated, tighten center screw securely to assure a positive seal.
4. Install power cord plug to heater.
5. Fill cooling system with coolant to the proper level. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).

The engine coolant temperature sensor threads into the top of the thermostat housing (Scheme 12) New sensors have sealant applied to the threads.

Scheme 12

1. Drain the cooling system below thermostat level. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).
2. Disconnect coolant temperature sensor electrical connector.
3. Remove coolant temperature sensor (Scheme 12)

1. Install coolant temperature sensor (Scheme 12) Tighten sensor to 7 N-m (60 in. lbs.).
2. Connect electrical connector to sensor.
3. Fill cooling system. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).

The engine coolant temperature sensor threads into a coolant passage on lower intake manifold near the thermostat (Scheme 15) New sensors have sealant applied to the threads.

Scheme 13

Scheme 14

Scheme 15

1. Drain cooling system below engine coolant temperature sensor level. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).
2. Remove power steering reservoir and relocate (Scheme 13) Do not disconnect hoses.
3. Remove ignition coil and bracket (Scheme 14)
4. Disconnect coolant sensor electrical connector (Scheme 15)
5. Remove coolant sensor (Scheme 15)

1. Install engine coolant temperature sensor (Scheme 15) Tighten sensor to 7 N-m (60 in. lbs.).
2. Connect electrical connector to sensor (Scheme 15)
3. Install ignition coil bracket (Scheme 14)
4. Install ignition coil (Scheme 14)
5. Install power steering reservoir (Scheme 13)
6. Fill cooling system. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).

The engine cooling thermostats are a wax pellet driven, reverse poppet choke type. The thermostat is mounted in a housing on the coolant outlet of the engine (Scheme 17) or (Scheme 19)

The engine cooling thermostat is a wax pellet driven, reverse poppet choke type. The thermostat is designed to provide the fastest warm up possible by preventing leakage through it and to guarantee a minimum engine operating temperature of 88 to 93°C (192 to 199°F). The thermostat also will automatically reach wide open so it will not restrict flow to the radiator as temperature of the coolant rises in hot weather to around 104°C (220°F). Above this temperature the coolant temperature is controlled by the radiator, fan, and ambient temperature, not the thermostat.

The thermostat is operated by a wax filled container (pellet) which is sealed. When heated coolant reaches a predetermined temperature, the wax expands enough to overcome the closing spring and water pump pressure, which forces the valve to open.

DIAGNOSIS AND TESTING - ENGINE COOLANT THERMOSTAT

The thermostat is operated by a wax filled chamber (pellet) which is sealed. When heated coolant reaches a predetermined temperature the wax pellet expands enough to overcome the closing spring and water pump pressure, which forces the valve to open. Coolant leakage into the pellet will cause a thermostat to fail open. Do not attempt to free up a thermostat with a screwdriver.

Thermostat diagnostics is included in powertrain control module's (PCM) programing for on-board diagnosis. The malfunction indicator light (MIL) will illuminate and a diagnostic trouble code (DTC) will be set when an "open too soon" condition occurs. Do not change a thermostat for lack of heater performance or temperature gauge position, unless a DTC is present. For other probable causes, (Refer to DIAGNOSIS AND TESTING ). Thermostat failing shut is the normal long term mode of failure, and normally, only on high mileage vehicles. The temperature gauge will indicate this (Refer to DIAGNOSIS AND TESTING ).

Scheme 16

Scheme 17

1. Drain cooling system below the thermostat level. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).
2. Remove radiator upper hose from the coolant outlet housing (Scheme 16)
3. Remove coolant outlet housing bolts and housing (Scheme 17)
4. Remove thermostat. Discard gasket and clean both gasket sealing surfaces.

1. Place a new gasket (dipped in clean water) on the coolant outlet connector surface. Position thermostat with air bleed at the 12 o'clock position in thermostat housing (Scheme 17)
2. Position the coolant outlet connector and gasket over the thermostat, making sure thermostat is seated in the thermostat housing.
3. Position outlet connector to thermostat housing and install bolts (Scheme 17) Tighten bolts to 28 N-m (250 in. lbs.).
4. Install the radiator upper hose to coolant outlet housing (Scheme 16)
5. Refill the cooling system. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).

Scheme 18

Scheme 19

1. Drain cooling system down below the thermostat level. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).
2. Remove radiator upper hose from coolant outlet connector (Scheme 18)
3. Remove coolant outlet connector bolts and connector (Scheme 19)
4. Remove thermostat from outlet connector.
5. Discard gasket and clean both gasket sealing surfaces.

Scheme 20

Scheme 21

1. To ensure proper seating of replacement thermostat, carefully remove the bulged metal from the wall of the outlet connector recess that was created during the staking procedure that held the OEM thermostat in place (Scheme 20) It is not necessary to restake the replacement thermostat into the connector.
2. Position thermostat to coolant outlet connector. Align the two locating notches on thermostat to the connector (Scheme 21) This position will ensure proper location of the thermostat air bleed.
3. Position a new gasket over the thermostat and connector making sure thermostat is in proper position and in the recess provided.
4. Install thermostat and connector assembly to the intake manifold (Scheme 19) Tighten bolts to 28 N.m (250 in. lbs.).
5. Install the radiator upper hose to coolant outlet connector (Scheme 18)
6. Refill the cooling system to the proper level. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).

Scheme 22

Scheme 23

Scheme 24

1. Disconnect negative cable from battery.
2. Remove radiator upper crossmember support. (Refer to GRILLE OPENING REINFORCEMENT - REMOVAL ).
3. Drain the cooling system. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).
4. Remove the radiator fans. (Refer to «REMOVAL»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__removal) ).
5. Disconnect coolant reserve/recovery hose.
6. Remove vapor purge solenoid from mounting bracket.
7. Disconnect upper and lower hoses from the radiator (Scheme 22) or (Scheme 23)
8. Remove the A/C condenser side brackets to radiator attaching screws (Scheme 24) Separate the condenser from the radiator by lifting upward to disengage from lower mounts (Scheme 24) Allow the condenser to rest in front of radiator.
9. Radiator can now be lifted free from engine compartment. Care should be taken not to damage radiator cooling fins or water tubes during removal.

1. Be sure the air seal is in position before radiator is installed. Slide radiator down into position. Seat the radiator with the rubber isolators into the mounting holes provided, with a 10 lbs. force.
2. Position air conditioning condenser onto the radiator lower mounts and install upper screws (Scheme 24) Tighten fasteners to 5 N.m (45 in. lbs.).
3. Install the radiator upper and lower hoses (Scheme 22) or (Scheme 23)
4. Connect the coolant reserve/recovery hose.
5. Connect the vapor purge solenoid to the mounting bracket.
6. Install the radiator fans. (Refer to «INSTALLATION»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__installation) ).
7. Install the radiator upper crossmember support. (Refer to GRILLE OPENING REINFORCEMENT - INSTALLATION ).
8. Fill the cooling system. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).
9. Connect negative cable to battery.

Note. It is not necessary to remove draincock during a routine coolant drain.

Scheme 25

1. Drain the cooling system. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).
2. Open the draincock by turning it counterclockwise until it stops.
3. Turn the draincock back (clockwise) 1/8 turn.
4. Pull the draincock (Scheme 25) from the radiator tank.

1. Align draincock stem to radiator tank opening.
2. Push draincock into the radiator tank opening.
3. Tighten the draincock by turning clockwise until it stops.
4. Fill the cooling system. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).

The cooling system pressure cap is located on the radiator. The cap construction includes; stainless steel swivel top, rubber seals, and retainer, main spring, and a spring loaded valve (Scheme 26)

Scheme 26

The cooling system is equipped with a pressure cap that releases excessive pressure; maintaining a range of 97-124 kPa (14-18 psi).

The cooling system will operate at higher than atmospheric pressure. The higher pressure raises the coolant boiling point thus, allowing increased radiator cooling capacity.

There is also a vent valve in the center of the cap. This valve also opens when coolant is cooling and contracting, allowing the coolant to return to cooling system from coolant reserve system tank by vacuum through a connecting hose. If valve is stuck shut, or the coolant recovery hose is pinched, the radiator hoses will be collapsed on cool down. Clean the vent valve (Scheme 26) and inspect coolant recovery hose routing, to ensure proper sealing when boiling point is reached.

The gasket in the cap seals the filler neck, so that vacuum can be maintained, allowing coolant to be drawn back into the radiator from the reserve tank. If the gasket is dirty or damaged, a vacuum may not be achieved, resulting is loss of coolant and eventual overheating due to low coolant level in radiator and engine.

DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE CAP TESTING

Dip the pressure cap in water. Clean any deposits off the vent valve or its seat and apply cap to end of the Pressure Cap Test Adaptor that is included with the Cooling System Tester 7700 (Scheme 27) Working the plunger, bring the pressure to 104 kPa (15 psi) on the gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi), replace the pressure cap.

Scheme 27

If the pressure cap tests properly while positioned on Cooling System Tester (Scheme 27), but will not hold pressure or vacuum when positioned on the filler neck. Inspect the filler neck and cap top gasket for irregularities that may prevent the cap from sealing properly.

DIAGNOSIS AND TESTING - RADIATOR CAP TO FILLER NECK SEAL

The pressure cap upper gasket (seal) pressure relief can be checked by removing the overflow hose at the radiator filler neck nipple (Scheme 28) Attach the Radiator Pressure Tool to the filler neck nipple and pump air into the radiator. Pressure cap upper gasket should relieve at 69-124 kPa (10-18 psi) and hold pressure at 55 kPa (8 psi) minimum.

Scheme 28

There is no need to remove the radiator cap at any time except for the following purposes

1. Check and adjust coolant freeze point.
2. Refill system with new coolant.
3. Conducting service procedures.
4. Checking for vacuum leaks.

Use only a mild soap to clean the pressure cap.

Hold the cap in your hand, top side up (Scheme 29) The vent valve at the bottom of the cap should open. If the rubber gasket has swollen, preventing the valve from opening, replace the cap.

Scheme 29

Hold the cleaned cap in your hand, upside down. If any light can be seen between vent valve and the rubber gasket, replace the cap. Do not use a replacement cap that has a spring to hold the vent shut.

A replacement cap must be of the type designed for coolant reserve systems. This design ensures coolant return to the radiator.

The dual radiator fans are mounted to the back side of the radiator (Scheme 32) The radiator fan consist of the fan blade, electric motor and a support shroud which are all serviced as an assembly.

Scheme 30

Scheme 31

There are no repairs to be made to the fan or shroud assembly. If the fan is warped, cracked, or otherwise damaged, it must be replaced as an assembly (Scheme 32)

Scheme 32

1. Remove the radiator upper crossmember. (Refer to GRILLE OPENING REINFORCEMENT - REMOVAL ).
2. Disconnect the radiator fan electrical connectors.
3. Remove radiator fan(s) retaining screw (Scheme 32)
4. Remove the radiator fan(s) by lifting upward to release from mounts.

1. Install the radiator fan(s) into mounts and attaching clips on the radiator.
2. Install radiator fan(s) attaching screws (Scheme 32) Tighten to 5 N.m (45 in. lbs.).
3. Connect the radiator fan(s) electrical connectors.
4. Install the radiator upper support crossmember. (Refer to GRILLE OPENING REINFORCEMENT - INSTALLATION ).
5. Install the upper radiator mounts to the cross-member bolts, if removed. Tighten to 8 N.m (70 in. lbs.).
6. Install the radiator upper hose to the support clip (2.4L engine).

The radiator fan relay is a solid state type and is located on the front bumper reinforcement (Scheme 33) Refer to WIRING DIAGRAMS for a circuit schematic.

The solid state radiator fan relay is controlled by the Powertrain Control Module (PCM) by way of a Pulse Width Modulated (PWM) signal. The relay control circuit supplies a 12 volt signal to the PCM. The PCM then pulses the ground circuit to achieve fan on time. The relay provides a voltage to the fan motors which is proportional to the pulse width it receives from the PCM. The duty cycle ranges from 30% for low speed operation, then ramps-up to 100% for high speed operation. This fan control system provides infinitely variable fan speeds, allowing for improved fan noise, A/C performance, better engine cooling, and additional vehicle power.

To control operation of the relay, the PCM looks at inputs from

1. Engine coolant temperature
2. A/C pressure transducer
3. Ambient temperature from the body controller
4. Vehicle speed
5. Transmission oil temperature

The PCM uses these inputs to determine when the fan should operate and at what speed. For further information on fan operation, (Refer to OPERATION ).

Scheme 33

1. Open hood.
2. Disconnect and isolate the battery negative cable.
3. Remove the radiator crossmember to front fascia closure panel.
4. Disconnect the relay electrical connector (Scheme 33)
5. Remove the rivet attaching the relay to the front bumper beam (Scheme 33)
6. Remove the relay.

1. Position relay and install a new rivet (Scheme 33)
2. Connect electrical connector to relay.
3. Install closure panel and attaching screws.
4. Connect negative cable to battery.

The water pump has a cast aluminum body and housing with a stamped steel impeller. The water pump bolts directly to the block (Scheme 34) The cylinder block to water pump seal is provided by a rubber O-ring. The water pump is driven by the engine timing belt.

Scheme 34

Scheme 35

Scheme 36

1. Disconnect negative cable from battery.
2. Raise vehicle on a hoist.
3. Remove the right inner splash shield.
4. Remove the accessory drive belts (Refer to «REMOVAL»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__removal) ).
5. Drain the cooling system (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).
6. Support engine from the bottom and remove right engine mount. (Refer to RIGHT MOUNT - REMOVAL ).
7. Remove right engine mount bracket (Scheme 35)
8. Remove the timing belt (Refer to REMOVAL ).
9. Remove timing belt idler pulley.
10. Hold camshaft sprocket with Special tool C-4687 and adaptor C-4687-1 while removing bolt. Remove both cam sprockets.
11. Remove the timing belt rear cover (Refer to REMOVAL ).
12. Remove the generator and bracket (Scheme 35)
13. Remove water pump to engine attaching screws (Scheme 36)

Clean gasket mating surfaces as necessary.

Replace water pump body assembly if it has any of these defects

1. Cracks or damage on the body.
2. Coolant leaks from the shaft seal, evident by wet coolant traces on the pump body.
3. Loose or rough turning bearing.
4. Impeller rubs either the pump body or the engine block.
5. Impeller loose or damaged.
6. Sprocket or sprocket flange loose or damaged.

1. Install new O-ring gasket in water pump body O-ring locating groove (Scheme 37)
2. Assemble pump body to block and tighten screws to 12 N.m (105 in. lbs.) (Scheme 36) Pressurize cooling system to 103.4 Kpa (15 psi) with pressure tester and check water pump shaft seal and O-ring for leaks.
3. Rotate pump by hand to check for freedom of movement.
4. Install the timing belt rear cover (Refer to TIMING BELT COVER(S) - INSTALLATION ).
5. Install camshaft sprockets and torque bolts to 101 N-m (75 ft. lbs.) while holding camshaft sprocket with Special tool C-4687 and adaptor C-4687-1.
6. Install timing belt idler pulley and torque mounting bolt to 61 N-m (45 ft. lbs.).
7. Install the timing belt (Refer to INSTALLATION ).
8. Install the generator mount bracket. (Scheme 35)
9. Install the generator.
10. Install right engine mount bracket and engine mount (Refer to RIGHT MOUNT - INSTALLATION ).
11. Fill the cooling system (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).
12. Install the accessory drive belts (Refer to «INSTALLATION»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__installation) ).
13. Lower vehicle and connect battery cable.

The water pump has a die-cast aluminum body and a plastic impeller. It bolts directly to the timing chain case cover, using a rubber seal for sealing (Scheme 38) It is driven by the accessory drive belt.

Scheme 37

Scheme 38

1. Drain the cooling system. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).
2. Remove the accessory drive belt shield.
3. Remove the accessory drive belt. (Refer to «REMOVAL»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__installation) ).
4. Remove water pump pulley bolts (Scheme 38)
5. Rotate pulley until openings in pulley align with water pump drive hub spokes (Scheme 39) Move pulley inward between pump housing and hub (Scheme 39)
6. Position pulley to allow access to water pump mounting bolts. Remove water pump mounting bolts (Scheme 40)
7. Remove water pump with the pulley loosely positioned between hub and the pump body.
8. Remove and discard the seal.
9. Clean seal groove and sealing surfaces on pump and timing chain case cover. Take care not to scratch or gouge sealing surfaces.

Clean gasket mating surfaces as necessary.

Replace the water pump if it has any of the following defects.

Scheme 39

1. Damage or cracks on the pump body.
2. Coolant leaks; this will be evident by a wet stream of coolant running down the pump body and components below. A thin stain below the weep hole reservoir slot (Scheme 41) is considered normal operation.
3. Impeller rubs inside of chain case cover.
4. Excessively loose or rough turning bearing.

Note. A weepage stain that is black, brown, or grey is considered normal, if it is dry. If the weep appears wet; pressure test the cooling system at 15-18 psi and observe the weep area. If weep area remains unchanged, do not replace the water pump for this condition. Replace the water pump, if a steady flow of engine coolant is evident from the weep hole/reservoir slot (Scheme 41) (shaft seal failure). Be sure to perform a thorough analysis before replacing water pump.

Scheme 40

1. Install new seal into water pump housing groove (Scheme 42)
2. Position the water pump pulley loosely between pump housing and drive hub (Scheme 39)
3. Install water pump and pulley to the timing chain case cover (Scheme 38) Tighten water pump bolts to 12 N.m (105 in. lbs.).
4. Position pulley on water pump hub. Install bolts and tighten to 28 N.m (250 in. lbs.) (Scheme 38)
5. Rotate pump by hand to check for freedom of movement.
6. Install the accessory drive belt. (Refer to «INSTALLATION»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__installation) ).
7. Install drive belt shield.
8. Fill the cooling system. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).

The 2.4L engine uses a metal tube to connect the engine block to the lower radiator hose and heater return (Scheme 43) The tube has an O-ring for block to tube sealing and bolts attach the tube to the engine block.

Scheme 41

Scheme 42

1. Drain the cooling system. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).
2. Remove radiator upper hose to access the hose connections at the inlet tube.
3. Remove radiator lower (Scheme 16) and heater hoses from the inlet tube (Scheme 44)
4. Remove the two fasteners that hold the inlet tube to the block.
5. Rotate tube while removing the tube from the engine block.

1. Inspect the O-ring for damage before installing the tube into the cylinder block (Scheme 43)
2. Lube O-ring with coolant and install inlet tube into the cylinder block opening (Scheme 43)
3. Install the two inlet tube fasteners and tighten to 12 N-m (105 in. lbs.).
4. Connect the radiator lower hose (Scheme 16) and heater hose to inlet tube (Scheme 44)
5. Install the radiator upper hose.
6. Fill the cooling system. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).

Scheme 43

Scheme 44

Scheme 45

1. Drain the cooling system. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).
2. Raise vehicle on hoist and remove the belt splash shield.
3. Remove the radiator lower hose from inlet tube (Scheme 45)
4. Remove the oil cooler outlet/heater return hose from inlet tube (only if equipped with engine oil cooler) see scheme 42
5. Remove the inlet tube bolts see scheme 43
6. Remove the inlet tube see scheme 43 Discard the O-ring seal.

1. Clean the inlet tube O-ring sealing surfaces on the timing cover housing and tube.
2. Apply Mopar(R) Dielectric Grease or equivalent to the O-ring before installation.
3. Position new O-ring seal on inlet tube see scheme 43
4. Install the inlet tube see scheme 43 Tighten bolts to 28 N-m (250 in. lbs.).
5. Connect radiator lower hose (Scheme 45) and heater return hose (if equipped with engine oil cooler) see scheme 42 to the inlet tube.
6. Install the drive belt splash shield and lower vehicle.
7. Fill the cooling system. (Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/cooling-fan/#engine-cooling-system-mechanical__standard-procedure-coolant-service) ).

See also:
• STANDARD PROCEDURE
• DIAGNOSIS AND TESTING
• REMOVAL
• INSTALLATION
• OPERATION