This procedure is a general overview and may vary slightly depending on the specific engine in your Caravan (3.0L, 3.3L, or 3.8L). Always consult a repair manual specific to your vehicle's year, make, model, and engine for detailed instructions and torque specifications.
Tools You'll Need:
* Repair Manual: Absolutely essential for torque specs, diagrams, and specific procedures.
* Jack and Jack Stands: Safely support the vehicle.
* Wheel Chocks: For added safety.
* Socket Set and Wrenches: Various sizes, including metric and possibly SAE.
* Ratchet and Extensions: To reach tight spots.
* Pliers: For various tasks.
* Screwdrivers: Phillips and flathead.
* New Water Pump: Ensure you get the correct part for your engine.
* New Thermostat (Recommended): While you're in there, replacing the thermostat is a good preventative measure.
* New Gasket(s): For the water pump and possibly other components.
* New Antifreeze/Coolant: Use the correct type for your vehicle.
* Drain Pan: To catch the coolant.
* Funnel: To refill the system.
* Gloves: To protect your hands.
* Safety Glasses: To protect your eyes.
General Steps (Consult your repair manual for specific details):
1. Safety First: Disconnect the negative battery cable. Raise the vehicle safely using a jack and jack stands, and secure the wheels with chocks.
2. Drain the Coolant: Locate the drain plug on the engine block and the radiator drain petcock. Place a drain pan underneath and carefully open both to drain the coolant.
3. Remove Accessory Components: This will vary depending on your engine, but you'll likely need to remove:
* Serpentine Belt: Use a belt tensioner tool to release tension and remove the belt.
* Fan and Fan Shroud (Possibly): May need to be removed to access the water pump.
* Pulley(s): Often attached to the water pump.
* Wiring and hoses: Disconnect any hoses or wiring connected to the water pump.
4. Remove the Water Pump: This is often held on by bolts. Carefully remove these bolts, noting their location and order if necessary. The pump itself may be stubborn; you might need a pry bar (carefully!) to loosen it.
5. Clean the Mounting Surface: Thoroughly clean the mating surfaces of the engine block and the water pump housing to ensure a good seal.
6. Install the New Water Pump: Apply a thin bead of gasket sealant (if specified by the manufacturer) to the new gasket and install the new water pump, ensuring it seats correctly. Tighten the bolts to the manufacturer's specified torque.
7. Reinstall Components: Carefully reinstall all the components you removed earlier, in reverse order. Ensure all hoses are correctly connected and clamped. Make sure the serpentine belt is properly routed and tensioned.
8. Refill the Cooling System: Carefully add the correct type and amount of antifreeze/coolant to the radiator and overflow reservoir.
9. Bleed the Cooling System: This is crucial to remove any air pockets that may have formed. Consult your repair manual for specific bleeding procedures. Often involves running the engine briefly, letting it cool, and adding more coolant as needed.
10. Test and Inspect: Run the engine for a while, monitoring the temperature gauge and checking for any leaks. Inspect the hoses and connections for any signs of leakage.
Important Notes:
* Torque Specifications: Incorrect torque can damage the engine block or the water pump. Use a torque wrench and follow the specifications in your repair manual.
* Gasket Sealant: Use only the type of sealant recommended by the manufacturer.
* Coolant Type: Use the correct type of coolant for your vehicle. Using the wrong type can damage your engine.
Again, this is a simplified overview. Always consult a repair manual specific to your 1996 Dodge Caravan for detailed instructions and torque specifications. If you are uncomfortable performing this repair, it's best to take your vehicle to a qualified mechanic. A botched water pump replacement can lead to significant engine damage.
