Caravan Hose and Water Pump Replacement (3.3/3.8 L)

• Symptoms
  
  • coolant leak,
  • water pump noises, or
  • preventative maintenance

• Tools Required
  
  • 15 mm box wrench (for belt removal)
  • 13 mm socket wrench
  • 10 mm socket wrench
  • alignment tool (long, thin tool that looks like punch)
  • pliers for hose clamps
  • #2 Phillips head screwdriver

1. Belt Removal
   See Caravan Belt and Tensioner Replacement for instructions on how to remove the belt.

2. Water Pump Replacement
   Removal and replacement of the water pump is straightforward:
   1. Drain coolant. There is a draincock on the left side of the radiator. Mine didn't work, so I just loosened the lower radiator hose to drain it.
   2. Remove plastic plug from splash shield and swing it out of the way. The one plug I had goes straight up into the sheet metal. (Maybe one of mine was missing, there might be two plugs.) Just pull it out with fingers.
   3. Remove pump pulley. Slide an alignment tool through one of the holes in the pulley to keep it from rotating, then remove three bolts.
   4. Remove five bolts from pump and remove.
   5. Reverse instructions to install pump.

3. Upper Radiator Hose Replacement Notes
   Remove the plastic shield in front of the radiator crossmember. There are 5 Phillips head screws and a bolt on each end. I replaced the original spring-type clamp with a worm (screw)-type clamp, so I won't have to remove the plastic shield next time.

4. Lower Radiator Hose Replacement Notes
   Lower radiator hose replacement is straightforward, from underneath the vehicle.

5. Bypass Hose Replacement Notes
   The bypass hose is a bit tricky. The upper part is easy to get to. The lower part can be accessed after you remove the oil filter. Lubricate the inside of the new hose first, I use a thin film of dish detergent. To push the new hose onto the lower fitting, push down on the top of the hose while twisting it. Use your left hand to stabilize the middle of the hose so it doesn't buckle.

   Use 5/8" heater hose.

6. Heater Hose Replacement Notes
   The hose that goes across the front of the engine is not hard to replace. Mopar carries a replacement 15 mm hose, though it's not molded.

   I didn't try to replace the two hoses that connect to the heater core.

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Last modified 16:28:58 CDT 22 June 2004.