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Saturday, April 21, 2012

How to Replace Water Pump on Stratus, Avenger and Sebring?

The Complete Procedure to replace Water Pump.

Please Note that this Procedure Covers all 1999 to 2005 Chrysler/Dodge Avenger, Chrysler Sebring Coupe and Dodge Stratus/ Stratus Coupe models.

The water pump replacing is for
2.0L and 2.4L Engines.
2.5L Engine.
And
2.7L & 3.0L Engine models.


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. 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.
  2. Drain the cooling system.
  3. 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 
    image
    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.


MORE HELP DIAGRAMS:---


  1. Rear timing belt cover
    Water pump 

    image
    Fig. Exploded view of the water pump mounting-2.0L engine



  1. Remove or disconnect the following: 

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

    image
    Fig. Exploded view of the water pump-2.4L engine



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.

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. 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.
  2. Drain the engine coolant.
  3. 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:
image
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.
----------------

Water pump Replacing For 2.7L Engine & 3.0L Engine:


  1. Drain the cooling system.
  2. Remove or disconnect the following: 

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

    image
    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.

3.0L Engine



  1. 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.


These details will help.
Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html



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