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Installation - Except SRT

Fig 1: Installing Water Pump
GC0033996Courtesy of DAIMLERCHRYSLER CORP.
  1. Clean all gasket surfaces.
  2. Position the water pump with a new gasket on the timing chain cover.
  3. Install the water pump bolts in the correct positions. Tighten the bolts to 35 N.m (26 ft. lbs.).
  4. Install the generator. (Refer to ELECTRICAL/CHARGING/GENERATOR - INSTALLATION) .
    Fig 2: Identifying Coolant By-Pass Hose & Lower Radiator Hose
    GC0033998Courtesy of DAIMLERCHRYSLER CORP.
  5. Install the belt tensioner. (Refer to COOLING/ACCESSORY DRIVE/BELT TENSIONERS - INSTALLATION) .
    Fig 3: Identifying Accessory Drive Belt Idler Pulley & Water Pump Pulley
    GC0033999Courtesy of DAIMLERCHRYSLER CORP.
  6. Install the water pump pulley (2) and bolts. Tighten the water pump pulley bolts to 10 N.m (89 in. lbs.).
  7. Install the idler pulley (1) and bolt. Tighten the idler pulley bolt to 10 N.m (89 in. lbs.).
    Fig 4: Identifying Coolant Bypass Hose & Lower Radiator Hose
    GC0033584Courtesy of DAIMLERCHRYSLER CORP.
  8. Connect the lower radiator hose (2) and coolant by-pass hose (1).
    Fig 5: Removing/Installing Accessory Drive Belt
    GC0033987Courtesy of DAIMLERCHRYSLER CORP.
  9. Rotate the belt tensioner counterclockwise and install the accessory drive belt.
  10. Release the belt tensioner and remove the wrench.
    Fig 6: Removing/Installing Radiator Fan
    GC0033979Courtesy of DAIMLERCHRYSLER CORP.
  11. Install the radiator fan. (Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION) .
    Fig 7: Identifying Engine Appearance Cover
    GC0032575Courtesy of DAIMLERCHRYSLER CORP.
  12. Install the engine cover (1). Align the engine cover retaining clips to the rubber mounts, and push down firmly to connect engine cover to rubber mounts.
    NOTE: To ease the installation of the engine cover, apply a small amount of lubricant to the engine cover rubber mounts.
  13. Install the air cleaner inlet tubes (2).
  14. Connect the negative battery cable.
  15. Fill the cooling system. (Refer to COOLING/ENGINE/COOLANT - STANDARD PROCEDURE) .
  16. Start the engine and check for coolant leaks.
  17. Recheck the coolant level.
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