Tuesday, November 22, 2011

How to replace Water Pump on Dodge Avenger, Sebring Coupe, Stratus Coupe Models?


Water pump is important part/component for car cooling system.Water pump maintenance is required,to keep water pump free from problems.But in case if it gets faulty then it has to be replaced.

If you need dis-assembly or replacement instructions for any other auto/car part, or you want to ask question related to your car/truck jeep problem then please leave the comment with your details, so I can provide you the required instructions and solutions.

The procedure to replace cars water pump is as follows :----

Water Pump


REMOVAL & INSTALLATION



CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

2.0L And 2.4L Engines



This engine uses a die-cast aluminum body water pump with a stamped steel impeller. The water pump bolts directly to the block. Cylinder block-to-water pump sealing is provided by a large rubber O-ring. The water pump is driven by the timing belt, that must be removed to service the water pump.
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect the negative battery cable from the left shock tower.
    NOTE
    The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.


    NOTE
    This procedure requires removing the engine timing belt and the auto-tensioner. The factory specifies that the timing marks should always be aligned before removing the timing belt. Set the engine at Top Dead Center (TDC) on No. 1 compression stroke. This should align all timing marks on the crankshaft sprocket and both camshaft sprockets.
  3. Drain the cooling system.
  4. Remove or disconnect the following:
    NOTE
    Do not disconnect the power steering fluid lines.


    WARNING
    With the timing belt removed, DO NOT rotate the camshaft or crankshaft or damage to the engine could occur.


    NOTE
    Do not allow the camshafts to turn when the camshaft sprockets are being removed.



    Right inner splash shield
    Accessory drive belts and support the engine
    Right motor mount
    Power steering pump bracket bolts and move the pump/bracket assembly aside



    Right engine mount bracket
    Timing belt front covers
    Timing belt tensioner and timing belt by loosening the tensioner screws



    Camshaft sprockets



    Rear timing belt cover
    Water pump

    Click image to see an enlarged view
    Fig. When installing the water pump, properly Install the O-ring to ensure a tight seal-2.0L and 2.4L engines
To install:
  1. Thoroughly clean all sealing surfaces. Replace the water pump if there are any cracks, signs of coolant leakage from the shaft seal, loose or rough turning bearings, damaged impeller or sprocket or sprocket flange loose or damaged.
  2. Install or connect the following:
    WARNING
    Be sure the O-ring is properly seated in the water pump groove before tightening the screws. An improperly located O-ring may cause damage to the O-ring and cause a coolant leak.



    New rubber O-ring into the water pump



    Water pump. Torque the bolts to 105 inch lbs. (12 Nm)
  3. Pressurize the cooling system to 15 psi (103.4 kPa) and check for leaks. If okay, release the pressure and continue the engine assembly process.
  4. Install or connect the following:
    NOTE
    DO NOT allow the camshafts to turn while the sprocket bolts are being tightened to maintain timing mark alignment.


    WARNING
    Do not attempt to compress the tensioner plunger with the tensioner assembly installed in the engine. This will cause damage to the tensioner and other related components. The tensioner MUST be compressed in a vise.



    Rear timing belt cover
    Camshaft sprockets. Torque the bolts to 75 ft. lbs. (101 Nm)



    Timing belt tensioner and timing belt. Properly tension the timing belt.
    Front upper and lower timing belt covers
    Right engine mount bracket and engine mount
    Crankshaft damper. Torque the center bolt to 105 ft. lbs. (142 Nm)
    Right inner splash shield
    Power steering pump bracket and power steering pump. Torque the bracket mounting bolts to 40 ft. lbs. (54 Nm)
    Accessory drive belts. Properly tension the drive belts
  5. Refill and bleed the cooling system.
  6. Start the engine and check for proper operation.
  7. Check and top off cooling system, if necessary.

2.0L Engine



This procedure requires removing the timing belt and auto-tensioner. The factory specifies that the timing marks should always be aligned before removing the timing belt. Set the engine at Top Dead Center (TDC) on the No. 1 cylinder compression stroke. This should align all timing marks on the crankshaft sprocket and both camshaft sprockets.
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
    CAUTION
    This operation must only be performed on a cold engine.
  3. Drain the engine coolant.
  4. Remove or disconnect the following:
    WARNING
    With the timing belt removed, DO NOT rotate the camshaft or crankshaft or damage to the engine may occur.



    Negative battery cable
    Right inner splash shield
    Accessory drive belts
    Properly support the engine and remove the right motor mount
    Timing belt, tensioner and camshaft sprockets



    Rear timing belt cover
    Water pump

    Click image to see an enlarged view
    Fig. Exploded view of the water pump mounting-2.0L engine
To install:
  1. Thoroughly clean all sealing surfaces.
  2. Replace the water pump if there are any cracks, signs of coolant leakage from the shaft seal, loose or rough turning bearings, damaged impeller or sprocket or loose or damaged sprocket flange.
  3. Install or connect the following:
    NOTE
    Be sure the O-ring is properly seated in the water pump groove before tightening the screws.



    New water pump O-ring



    Water pump and torque the bolts to 105 inch lbs. (12 Nm) in a crisscross pattern
  4. Using a cooling system pressure tester, pressurize the cooling system to 15 psi (103 kPa) and check for leaks. If okay, release the pressure and continue the engine assembly process.
  5. Rotate the water pump by hand to check for freedom of movement.
  6. Install or connect the following:
    WARNING
    DO NOT allow the camshafts to turn while the sprocket bolts are being tightened.


    WARNING
    Do not attempt to compress the tensioner plunger with the tensioner assembly installed in the engine. This will cause damage to the tensioner and other related components. The tensioner MUST be compressed in a vise.



    Rear timing belt cover
    Camshaft sprocket(s), timing belt and tensioner



    Timing belt covers
    Right engine mount bracket and mount
  7. Remove the engine support.

    Crankshaft damper
    Right inner splash shield
    Accessory drive belts
  8. Refill and bleed the cooling system.
  9. Start the engine and check for proper operation.
  10. Check and top off the cooling system, if necessary.

2.4L Engine



  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
    CAUTION
    This operation must only be performed on a cold engine.
  3. Drain the cooling system.
  4. Remove or disconnect the following:

    Negative battery cable
    Timing belt tensioner pulley
    Alternator brace
    Water pump and discard the gasket and O-ring

    Click image to see an enlarged view
    Fig. Exploded view of the water pump-2.4L engine
To install:
  1. Clean all mating surfaces of any residual gasket material
  2. Install or connect the following:

    New O-ring gasket
    Water pump and torque the bolts to 117 inch lbs. (14 Nm)
    Alternator brace and torque the bolts to 17 ft. lbs. (23 Nm)
    Timing belt tensioner pulley
    Negative battery cable
  3. Fill the cooling system to the proper level.
  4. Start the vehicle, check for leaks and repair if necessary.
This engine uses a die-cast aluminum body water pump with a stamped steel impeller. The water pump bolts directly to the block. Cylinder block-to-water pump sealing is provided by a large rubber O-ring. The water pump is driven by the timing belt that must be removed to service the water pump.
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable from the left shock tower.
    NOTE
    The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.


    NOTE
    This procedure requires removing the engine timing belt and the auto-tensioner. The factory specifies that the timing marks should always be aligned before removing the timing belt. Set the engine at Top Dead Center (TDC) on No. 1 compression stroke. This should align all timing marks on the crankshaft sprocket and both camshaft sprockets.
  3. Drain the cooling system.
  4. Remove or disconnect the following:
    NOTE
    Do not disconnect the power steering fluid lines.


    WARNING
    With the timing belt removed, DO NOT rotate the camshaft or crankshaft or damage to the engine could occur.


    NOTE
    Do not allow the camshafts to turn when the camshaft sprockets are being removed.



    The right inner splash shield
    The accessory drive belts and support the engine
    The right motor mount
    The power steering pump bracket bolts and move the pump/bracket assembly aside



    The right engine mount bracket
    The timing belt front covers
    The timing belt tensioner and timing belt by loosening the tensioner screws



    The camshaft sprockets



    The rear timing belt cover
    The water pump

    Click image to see an enlarged view
    Fig. When installing the water pump, properly install the O-ring to ensure a tight seal-2.4L engine
To install:
  1. Thoroughly clean all sealing surfaces. Replace the water pump if there are any cracks, signs of coolant leakage from the shaft seal, loose or rough turning bearings, damaged impeller or sprocket or sprocket flange loose or damaged.
  2. Install a NEW rubber O-ring into the water pump. 
    NOTE
    Be sure the O-ring is properly seated in the water pump groove before tightening the screws. An improperly located O-ring may cause damage to the O-ring and cause a coolant leak.
  3. Install the water pump. Torque the bolts to 105 inch lbs. (12 Nm).
  4. Pressurize the cooling system to 15 psi (103.4 kPa) and check for leaks. If no leaks are found, release the pressure and continue the engine assembly process.
  5. Install or connect the following:
    NOTE
    DO NOT allow the camshafts to turn while the sprocket bolts are being tightened to maintain timing mark alignment.


    WARNING
    Do not attempt to compress the tensioner plunger with the tensioner assembly installed in the engine. This will cause damage to the tensioner and other related components. The tensioner MUST be compressed in a vise.



    The rear timing belt cover
    The camshaft sprockets. Torque the bolts to 75 ft. lbs. (101 Nm)



    The timing belt tensioner and timing belt. Properly tension the timing belt.
    The front upper and lower timing belt covers
    The right engine mount bracket and engine mount
    The crankshaft damper. Torque the center bolt to 105 ft. lbs. (142 Nm)
    The right inner splash shield
    The power steering pump bracket and power steering pump. Torque the bracket mounting bolts to 40 ft. lbs. (54 Nm)
    The accessory drive belts. Properly tension the drive belts
  6. Refill and bleed the cooling system.
  7. Start the engine and check for proper operation.
  8. Check and top off cooling system, if necessary.

2.5L Engine



This procedure requires removing the timing belt and auto-tensioner. Set the engine at Top Dead Center (TDC) on the No. 1 cylinder compression stroke. This should align all timing marks on the crankshaft sprocket and both camshaft sprockets.
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
    CAUTION
    This operation must only be performed on a cold engine.
  3. Drain the engine coolant.
  4. Remove or disconnect the following:

    Negative battery cable
    Accessory drive belts and crankshaft damper
    Support the engine and remove the right engine mount
    Timing belt covers
    Timing belt and tensioner
    Water pump mounting bolts
    Water pump
To install:
Click image to see an enlarged view
Fig. Exploded view of the water pump mounting-2.5L engine
  1. Thoroughly clean all sealing surfaces. Inspect the pump for damage or cracks, signs of coolant leakage at the vent and excessive looseness or rough turning bearing. Any problems require a new pump.
  2. Install or connect the following:
    WARNING
    Wet the O-ring with water to make installation easier; DO NOT use oil or grease.


    NOTE
    Fit the pump inlet opening over the water pipe and press the assembly together to force the pipe into the water pump.



    New water inlet pipe O-ring.



    New water pump gasket



    Water pump and torque the pump-to-engine bolts to 20 ft. lbs. (27 Nm)
    Timing belt and timing belt tensioner. Set the timing belt tension.
    Timing belt covers
    Right engine mount. Remove the floor jack and engine block from underneath the engine.
    Crankshaft damper
    Accessory drive belts and adjust tension
    Negative battery cable
  3. Fill and bleed the engine cooling system.
  4. Start the engine and verify proper operation.
The water pump bolts directly to the engine block using a gasket for pump-to-block sealing. The pump is serviced as a unit. The 2.5L engine uses metal piping beyond the lower radiator hose to route coolant to the suction side of the water pump, located in the -V- of the cylinder banks. These pipes also have connections for thermostat bypass and heater return coolant hoses. The pipes use O-rings for sealing.
The water pump is driven by the timing belt which must be removed to service the water pump. Timing belt covers must be removed to access the timing belt.
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect the negative battery cable from the left shock tower.
    NOTE
    The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
  3. Drain the cooling system.
    NOTE
    This procedure requires removing the engine timing belt and the auto-tensioner. To help assure proper alignment at assembly, it may be helpful to set the engine at Top Dead Center (TDC) on No. 1 compression stroke. This should align all timing marks on the crankshaft sprocket and both camshaft sprockets.
  4. Remove or disconnect the following:

    Accessory drive belts
    Crankshaft damper
    Right engine mount by safely supporting the engine
    Timing belt covers, in this order: upper left, upper right and lower covers
    Timing belt and tensioner
    Water pump by separating it from the water inlet pipe
To install:
Click image to see an enlarged view
Fig. Exploded view of the water pump mounting-2.5L engine
  1. Thoroughly clean all sealing surfaces. Inspect the pump for damage or cracks, signs of coolant leakage at the vent and excessive looseness or rough turning bearing. Any problems require a new pump.
  2. Install or connect the following:

    New O-ring on the water inlet pipe by wetting it with water
    New gasket on the water pump
    Water pump. Torque the bolts to 20 ft. lbs. (27 Nm)
    Timing belt and timing belt tensioner by adjusting tension
    Timing belt covers
    Right engine mount
    Crankshaft damper
    Accessory drive belts by adjusting tension
    Negative battery cable
  3. Refill and bleed the cooling system.
  4. Start the engine and verify proper operation.

2.7L Engine



  1. Before servicing the vehicle, refer to the Precautions section.
  2. Drain the cooling system.
  3. Remove or disconnect the following:

    Negative battery cable
    Timing chain cover
    Timing chain and guides
    Water pump and discard the gasket

    Click image to see an enlarged view
    Fig. Water pump-2.7L engine
To install:
  1. Clean all mating surfaces of any residual gasket material.
  2. Install or connect the following:

    Water pump with a new gasket and torque the bolts to 105 inch lbs. (12 Nm)
    Timing chain guides and chain
    Timing chain cover
    Negative battery cable
  3. Fill the cooling system to the proper level.
  4. Start the vehicle, check for leaks and repair if necessary.
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the cooling system.
  3. Remove or disconnect the following:

    The negative battery cable
    The timing chain cover
    The timing chain and guides
    The water pump and discard the gasket

    Click image to see an enlarged view
    Fig. Water pump-2.7L engine
To install:
  1. Clean all mating surfaces of any residual gasket material.
  2. Install or connect the following:

    The water pump with a new gasket and torque the bolts to 105 inch lbs. (12 Nm)
    The timing chain guides and chain
    The timing chain cover
    The negative battery cable
  3. Fill the cooling system to the proper level.
  4. Start the vehicle, check for leaks and repair if necessary.

3.0L Engine



  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
    CAUTION
    This operation must only be performed on a cold engine.
  3. Drain the cooling system.
  4. Remove or disconnect the following:

    Negative battery cable
    Timing belt
    Thermostat and bracket
    Water pump and discard the gasket and O-ring
To install:
  1. Install or connect the following:
    NOTE
    Lubricate O-ring with engine coolant


    NOTE
    Be sure to torque the bolts in the proper sequence



    Water pump with a new O-ring and gasket and torque the bolts to 17 ft. lbs. (23 Nm)



    Bracket and torque the bolts to 17 ft. lbs. (23 Nm)



    Click image to see an enlarged view
    Fig. Torque sequence of engine mount bracket bolts-3.0L engine


    Thermostat
    Timing belt
    Negative battery cable
  2. Fill the cooling system to the proper level.
  3. Start the vehicle, check for leaks and repair if necessary.

-----------
This will help.Thanks.
-------------
For more car related problem troubleshooting:---

This are the sections, you can go through and click the link to read its troubleshooting.

---------

The car will not start?

-----------------

Car will not crank?


-----------

Car has no spark?


-------------

How to troubleshoot car battery?

-----------------

How to test starter solenoid?

http://schematicsdiagram.blogspot.com/2011/06/how-to-test-starter-solenoid.html

--------------------

How to test cars starter?

http://schematicsdiagram.blogspot.com/2011/06/how-to-test-cars-starter.html

How to replace starter in car?



-----------

car will turn over but will not start?



-----------------

Car wont start?


----------

No comments:

Post a Comment