1996 CHRYSLER VOYAGER transmission fluid

DESCRIPTION AND OPERATION
CLUTCH RELEASE SYSTEM
CLUTCH CABLE Ð LHD
The manual transaxle clutch release system has a
unique self-adjusting mechanism to compensate for
clutch disc wear (Fig. 7). This adjuster mechanism is
located within the clutch cable assembly. The preload
spring maintains tension on the cable. This tension
keeps the clutch release bearing continuously loaded
against the fingers of the clutch cover assembly.
HYDRAULIC CLUTCH Ð RHD
Leverage, clamping force, and friction are what
make the clutch work. The disc serves as the friction
element and a diaphragm spring and pressure plate
provide the clamping force. The clutch pedal, hydrau-
lic linkage, release lever and bearing provide the
leverage to disengage and engage the modular clutch
assembly.
The modular clutch assembly contains the cover,
diaphragm spring, pressure plate, disc and flywheel
in one unit. The modular clutch also uses a drive
plate and is bolted to and driven by the drive plate.
The clutch linkage uses hydraulic pressure to oper-
ate the clutch. The clutch master cylinder push rod is
connected to the clutch pedal and the slave cylinder
push rod is connected to the release lever in the
clutch housing.
Depressing the clutch pedal develops fluid pressure
in the clutch master cylinder. This pressure is trans-
mitted to the slave cylinder through a connecting
line. In turn, the slave cylinder operates the clutch
release lever.
The clutch release bearing is mounted on the
transmission front bearing retainer. The bearing is
attached to the release lever, which moves the bear-
ing into contact with the clutch cover diaphragm
spring.Slave cylinder force causes the release lever to
move the release bearing into contact with the dia-
phragm spring. As additional force is applied, the
bearing presses the diaphragm spring fingers inward
on the fulcrums. This action moves the pressure
plate rearward relieving clamp force on the disc. The
clutch disc is disengaged and not driven at this point.
The process of clutch engagement is simply the
reverse of what occurs during disengagement. Releas-
ing pedal pressure removes clutch linkage pressure.
The release bearing moves away from the diaphragm
spring which allows the pressure plate to exert
clamping force on the clutch disc.
CLUTCH PEDAL POSITION SWITCH
The clutch pedal position switch functions as a
safety interlock device. It prevents possible engine
cranking with the clutch engaged.
The clutch pedal position switch is wired in series
between the starter relay coil and the ignition
switch.
The clutch pedal position switch is mounted to a
bracket located behind the clutch pedal. The switch
is held in place by four plastic wing tabs.
The clutch pedal position switch IS NOT adjust-
able. The pedal blade contacts the switch in the down
position (Fig. 8).
DIAGNOSIS AND TESTING
CLUTCH PEDAL POSITION SWITCH
CLUTCH PEDAL POSITION
SWITCH±ELECTRICAL TEST
Disconnect clutch pedal position switch harness
from instrument panel wiring harness. Using an
ohmmeter, check for continuity between the two ter-
minals in the connector on the switch harness. There
should be no continuity between the terminals when
Fig. 7 Clutch Cable Ð LHD
Fig. 8 Clutch Pedal Position Switch and
Components Ð LHD Shown
6 - 4 CLUTCHNS/GS

The instrument cluster is equipped with the follow-
ing warning lamps.
²Lift Gate Ajar
²Low Fuel Level
²Low Windshield Washer Fluid Level
²Cruise
²Battery Voltage
²Fasten Seat Belt
²Door Ajar
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
NS vehicle instrument clusters are equipped with a
self diagnostic test feature to help identify electronic
problems. Prior to any test, perform Self Diagnostic
Test. The self diagnostic system monitors the CCD
bus messages. If an electronic problem occurs, a
Diagnostic Trouble Code (DTC) will be displayed in
the odometer window of the cluster.
The following CCD bus messages are continuously
monitored by the diagnostic system:
²Body Control Module
²Powertrain Control Module
²Transmission Control Module, if equipped
HEADLAMP SWITCH
Using a Digital Multimeter, equipped with a diode
test to perform the Headlamp Switch Test below (Fig.
1).
Switch position possibilities are open (no continu-
ity), continuity, resistance value in ohms, or diode
test. Use the values in the third column to determine
meter setting. If Headlamp Switch is not within spec-
ifications replace as necessary.
The Chrysler Town and Country is available with
optional Automatic Headlamps. For diagnosis, refer
to the proper Body Diagnostic Procedures Manual.
SELF DIAGNOSTIC TEST
To activate self diagnostic program:
(1) With the ignition switch in the OFF position,
depress the TRIP and RESET buttons.
(2) While holding the TRIP and RESET button
turn the ignition switch to the ON position.
(3) Continue to hold the TRIP and RESET buttons
until the word CODE appears in the odometer win-
dows (about five seconds) then release the buttons. If
a problem exists, the system will display Diagnostic
Trouble Codes (DTC's). If no problem exists, the code
999 (End Test) will momentarily appear.
DIM TEST
When CHEC-0 is displayed in the odometer win-
dow, the cluster's vacuum fluorescent (VF) displayswill dim down. If the VF display brightness does no
change, a problem exists in the cluster.
Fig. 1 Headlamp Switch Test
8E - 2 INSTRUMENT PANEL AND SYSTEMSNS
DESCRIPTION AND OPERATION (Continued)

8W-15 GROUND DISTRIBUTION
Component PageA/C Compressor Clutch....................8W-15-2, 3
A/C Heater Control........................8W-15-4
Airbag Control Module......................8W-15-4
All Wheel Drive Solenoid....................8W-15-13
Ash Receiver Lamp........................8W-15-6
Automatic Day/Night Mirror...................8W-15-5
AW4B13..............................8W-15-13
AWS1................................8W-15-13
Battery..............................8W-15-2, 3
Body Control Module.......................8W-15-6
Brake Pressure Switch......................8W-15-8
BS08.................................8W-15-5
BS31.................................8W-15-3
BS40.................................8W-15-3
BS41.................................8W-15-3
Center High Mounted Stop Lamp...............8W-15-14
Cigar/Accessory Relay.......................8W-15-7
Clockspring.............................8W-15-4
Clutch Switch............................8W-15-8
Combination Flasher/DRL Module...............8W-15-6
Controller Anti-Lock Brake....................8W-15-4
Crank Case Heater........................8W-15-3
CS06..............................8W-15-11, 12
Data Link Connector....................8W-15-2, 4, 12
Door Lock Relay..........................8W-15-6
Door Unlock Relay.........................8W-15-6
Downstream Heated Oxygen Sensor..............8W-15-5
Driver Door Arm/Disarm Switch.............8W-15-11, 12
Driver Door Courtesy Lamp...................8W-15-7
Driver Door Lock Switch..................8W-15-11, 12
Driver Door Unlock Relay....................8W-15-6
Driver Heated Seat Back.....................8W-15-9
Driver Heated Seat Cushion...................8W-15-9
Driver Heated Seat Module...................8W-15-9
Driver Heated Seat Switch....................8W-15-9
Driver Power Mirror........................8W-15-4
Driver Power Seat Switch....................8W-15-5
Driver Power Window Switch..................8W-15-7
DS01.................................8W-15-7
EC1C19...............................8W-15-5
Engine Speed Sensor.......................8W-15-3
ES01.................................8W-15-3
ES02.................................8W-15-3
ES11 .................................8W-15-2
ES12.................................8W-15-3
ES18.................................8W-15-2
ES23.................................8W-15-2
ES30.................................8W-15-3
ES31.................................8W-15-3
Front Blower Motor Relay....................8W-15-7
Front Cigar Lighter/Power Outlet...............8W-15-4
Fuel Heater.............................8W-15-3
Fuel Heater Relay.........................8W-15-3
Fuel Tank Module........................8W-15-13
G100................................8W-15-2, 3
G101.................................8W-15-2
G102................................8W-15-2, 3
G103................................8W-15-2, 3
G104.................................8W-15-4
G200.................................8W-15-4
G201.................................8W-15-4
G202.................................8W-15-5
G204.................................8W-15-4
G300...........................8W-15-5, 6, 7, 8, 9
G301............................8W-15-10, 11, 12
G302.................................8W-15-13
G400.................................8W-15-14
Headlamp Dimmer Switch....................8W-15-4
Headlamp Switch........................8W-15-4, 6
Headlamp Washer........................8W-15-10
High Note Horn.......................8W-15-11, 12
Hood Ajar Switch.........................8W-15-10
HS1..................................8W-15-9
HS3..................................8W-15-9
HS5D B09..............................8W-15-9
HS5P B56..............................8W-15-9
Ignition Switch.........................8W-15-4, 6
Instrument Cluster.......................8W-15-4, 6
Junction Block...........................8W-15-6
Key-In Halo Lamp.........................8W-15-6
Left Combination Relay.....................8W-15-13Component PageLeft Door Speaker.........................8W-15-5
Left Front Park/Turn Signal Lamp...............8W-15-7
Left Headlamp...........................8W-15-8
Left Headlamp Leveling Motor.................8W-15-8
Left High Headlamp........................8W-15-8
Left Liftgate Flood Lamp....................8W-15-14
Left Low Headlamp........................8W-15-8
Left Rear Door Ajar Switch...................8W-15-13
Left Rear Lamp Assembly....................8W-15-13
Left Rear Speaker.........................8W-15-5
Left Repeater Lamp........................8W-15-5
Left Speed Control Switch....................8W-15-4
Left Stop/Turn Signal Relay..................8W-15-13
License Lamp...........................8W-15-14
Liftgate Ajar Switch.......................8W-15-14
Liftgate Arm/Disarm Switch..................8W-15-14
Low Coolant Level Switch....................8W-15-3
Low Note Horn..........................8W-15-10
Low Washer Fluid Switch.................8W-15-11, 12
Memory Power Seat Switch..................8W-15-5, 9
Memory Seat/Mirror Module.................8W-15-5, 9
Memory Set Switch........................8W-15-7
Message Center...........................8W-15-6
Name Brand Speaker Relay...................8W-15-6
Needle Movement Sensor.....................8W-15-3
Overhead Console......................8W-15-11, 12
Passenger Door Arm/Disarm Switch.............8W-15-10
Passenger Door Courtesy Lamp.................8W-15-7
Passenger Door Lock Switch..................8W-15-10
Passenger Heated Seat Back...................8W-15-9
Passenger Heated Seat Cushion.................8W-15-9
Passenger Heated Seat Module.................8W-15-9
Passenger Heated Seat Switch.................8W-15-9
Passenger Power Mirror.....................8W-15-4
Passenger Power Seat Switch................8W-15-5, 12
Passenger Power Window Switch................8W-15-7
Power Distribution Center.................8W-15-2, 3, 7
Power Folding Mirror Switch..................8W-15-6
Power Mirror Switch.......................8W-15-6
Powertrain Control Module..................8W-15-2, 3
Radiator Fan Disconnect.....................8W-15-3
Radiator Fan No. 1........................8W-15-2
Radiator Fan No. 2........................8W-15-2
Radiator Fan Relay........................8W-15-2
Radiator Fan Relay No. 1.....................8W-15-3
Radio.................................8W-15-5
Rear Blower Front Control Switch...............8W-15-4
Rear Blower Rear Control Switch...............8W-15-13
Rear Cigar Lighter/Power Outlet...............8W-15-13
Rear Window Defogger.....................8W-15-14
Rear Wiper Motor.........................8W-15-14
Remote Keyless Entry Module..................8W-15-4
RF3E40...............................8W-15-2
RFS2.................................8W-15-2
Right Combination Relay....................8W-15-13
Right Door Speaker........................8W-15-5
Right Front Park/Turn Signal Lamp.............8W-15-10
Right Headlamp..........................8W-15-10
Right Headlamp Leveling Motor................8W-15-10
Right High Headlamp......................8W-15-10
Right Liftgate Flood Lamp...................8W-15-14
Right Low Headlamp......................8W-15-10
Right Rear Door Ajar Switch..................8W-15-13
Right Rear Lamp Assembly...................8W-15-13
Right Rear Speaker........................8W-15-5
Right Repeater Lamp......................8W-15-10
Right Speed Control Switch...................8W-15-4
Right Stop/Turn Signal Relay.................8W-15-13
Seat Belt Switch..........................8W-15-8
Sentry Key Immobilizer Module.................8W-15-4
Stop Lamp Switch.......................8W-15-6, 7
Traction Control Switch......................8W-15-6
Trailer Tow Connector......................8W-15-13
Transmission Control Module..................8W-15-2
Transmission Control Relay...................8W-15-2
Universal Garage Door Opener..............8W-15-11, 12
Upstream Heated Oxygen Sensor................8W-15-2
Vehicle Speed Control Servo...................8W-15-2
Wiper Module............................8W-15-5
Wiper On Relay...........................8W-15-7
NS/GS8W - 15 GROUND DISTRIBUTION 8W - 15 - 1

8W-40 INSTRUMENT CLUSTER
Component Page
A/C Heater Control....................8W-40-4
AW4B13............................8W-40-2
Body Control
Module........8W-40-2, 3, 4, 5, 6, 7, 8, 9, 10, 11
BS05........................8W-40-5, 6, 8, 10
BS06........................8W-40-5, 6, 8, 10
BS30...............................8W-40-7
BS40...............................8W-40-7
Clockspring......................8W-40-10, 11
Cluster Illumination Lamps.............8W-40-4
Cruise Indicator Lamp..............8W-40-10, 11
Data Link Connector...................8W-40-9
Door Ajar Indicator Lamp...............8W-40-3
Driver Door Ajar Switch................8W-40-3
Electronic PRNDL Indicator.............8W-40-5
Engine Coolant Temperature Gauge.....8W-40-8, 9
Engine Coolant Temperature Sensor.....8W-40-8, 9
Engine Speed Sensor...................8W-40-7
ES13........................8W-40-5, 6, 8, 10
ES14........................8W-40-5, 6, 8, 10
ES30...............................8W-40-7
Fuel Gauge..........................8W-40-2
Fuel Tank Module.....................8W-40-2
Fuse 2 (JB)..............8W-40-2, 3, 4, 5, 6, 8, 10
Fuse 28 (PDC)........................8W-40-2
G200...............................8W-40-2
G300...............................8W-40-4
G301...............................8W-40-7
G302...............................8W-40-3
G400...............................8W-40-3Component Page
Ignition Switch.....................8W-40-2, 4
Instrument Cluster............8W-40-2, 3, 4, 5, 6,
7, 8, 9, 10, 11
Junction Block...........8W-40-2, 3, 4, 5, 6, 8, 10
Left Rear Door Ajar Switch..............8W-40-3
Left Speed Control Switch...........8W-40-10, 11
Liftgate Ajar Indicator Lamp.............8W-40-3
Liftgate Ajar Switch...................8W-40-3
Low Fuel Warning Indicator Lamp........8W-40-2
Low Washer Fluid Level
Indicator Lamp.................8W-40-10, 11
Low Washer Fluid Switch...........8W-40-10, 11
Memory Seat/Mirror Module.............8W-40-2
Odometer............................8W-40-5
Passenger Door Ajar Switch.............8W-40-3
Power Distribution Center..............8W-40-2
Powertrain Control
Module..............8W-40-5, 6, 7, 8, 9, 10, 11
PS01............8W-40-2, 3, 4, 5, 6, 7, 8, 9, 10, 11
PS02............8W-40-2, 3, 4, 5, 6, 7, 8, 9, 10, 11
Right Rear Door Ajar Switch.............8W-40-3
Right Speed Control Switch..........8W-40-10, 11
Seat Belt Indicator Lamp...............8W-40-4
Seat Belt Switch......................8W-40-4
Speedometer.......................8W-40-6, 7
Tachometer........................8W-40-6, 7
Transmission Control Module..........8W-40-5, 6
Trip Odometer........................8W-40-5
Vehicle Speed Sensor.................8W-40-6, 7
Voltage Indicator Lamp...............8W-40-8, 9
NS/GS8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1

Component/
GroundColor Location Fig.
Left Rear
Reading LampGY At Lamp 17
Left Rear
Sliding Door
ContactBK LT B-Pillar 14
Left Rear
Sliding Door
Lock MotorBK At Motor N/S
Left Rear
SpeakerBK At Speaker 21
Left Rear Vent
MotorNAT At Motor 21
Left Rear Wheel
Speed SensorGY Center Rear of
Floor Pan16
Left Repeater
LampGY At Lamp N/S
Left Speed
Control SwitchLeft Side of
Steering Wheel
Pad11
Left Stop/Turn
Signal RelayBK LT Quarter
PanelN/S
Left Visor/Vanity
LampBK At Lamp 17
License Lamp GY At Lamps 23
Liftgate Ajar
SwitchBK At Latch 23
Liftgate
Arm/Disarm
SwitchGY At Key Cylinder 23
Liftgate Lock
MotorBK At Motor 23
LJ01 BK LT Quarter
Panel21
Low Note Horn BK LT Frame Rail 4
Low Washer
Fluid Level
SensorBK Bottom of
Reservior4
MAP Sensor
2.4LBK On Intake N/S
MAP Sensor
3.3L, 3.8LBK Near Throttle
Body9
Memort
Seat/Mirror
ModuleBK RT Front of
Floor Pan16
Memory Set
SwitchBL At Switch 19Component/
GroundColor Location Fig.
Message Center BL Rear of
Message
Center11
Mode Door
ActuatorBK LT Side of
HVAC15
Multi Function
SwitchBK Rear of Switch 11
Name Brand
Speaker RelayLT/GY LT of Steering
ColumnN/S
Output Shaft
Speed SensorGY Front of
Transmission7, 9
Overhead
ConsoleRD Front of
Console17
P18 GY RT of Steering
Column12
P30 BK RT Side of
HVAC10
P34 GY RT of Steering
Column12
P50 NAT Right Side of
HVAC Taped to
Harness10
Park Brake
SwitchNAT Top of Park
BrakeN/S
Park/Neutral
Positon SwitchBK Front of
TransmissionN/S
Passenger
AirbagYL Rear of Airbag 11
PDC C1 NAT Bottom of PDC 2
PDC C2 OR Bottom of PDC 2
PDC C3 DK/
GNBottom of PDC 2
PDC C4 BK Bottom of PDC 2
PDC C5 LT/GY Bottom of PDC 2
PDC C6 LT/GN Bottom of PDC 3
PDC C7 LT/GY Bottom of PDC 3
PDC C8 BL Bottom of PDC 3
Power Folding
Mirror SwitchBK At Switch N/S
Power Mirror
SwitchBK Rear of Switch 11
Power Steering
Pressure SwitchBK RT Side of
Engine
CompartmentN/S
8W - 90 - 34 8W - 90 CONNECTOR/GROUND LOCATIONSNS/GS
DESCRIPTION AND OPERATION (Continued)

POWER STEERING PUMP FLOW AND
PRESSURE TEST PROCEDURE
(1) Check power steering pump drive belt tension
and adjust as necessary.
(2) Disconnect power steering fluid pressure hose,
at power steering pump. Use a container for dripping
fluid.
(3) Connect Pressure Gauge, Special Tool from kit
6815 to both hoses using adapter fittings. Connect
spare pressure hose, to power steering pump pres-
sure hose fitting.
(4) Completely open valve on Special Tool 6815.
(5) Start engine and let idle long enough to circu-
late power steering fluid through flow/pressure test
and get air out of fluid. Then shut off engine.
(6) Check power steering fluid level, and add fluid
as necessary. Start engine again and let idle.
(7) Pressure gauge should read below 862 kPa
(125 psi), if above, inspect the hoses for restrictions
and repair as necessary. The initial pressure reading
should be in the range of 345-552 kPa (50-80 psi).
The flow meter should read between 1.3 and 1.9
GPM
CAUTION: The following test procedure involves
testing power steering pump maximum pressure
output and flow control valve operation. Do not
leave valve closed for more than 5 seconds as the
pump could be damaged.
(8) Close valve fully three times and record high-
est pressure indicated each time.All three read-
ings must be within specifications and within
345 kPa (50 psi) of each other.
NOTE: Power steering pump maximum relief pres-
sure is 9653 to 10342 kPa (1400 to 1500 psi.).
²If power steering pump pressures are within the
specifications but not within 345 kPa (50 psi) of each
other, then replace power steering pump.
²If pressures are within 345 kPa (50 psi) of each
other but below specifications, then replace power
steering pump.
CAUTION: Do not force the pump to operate
against the stops for more than 5 seconds at a time
because, pump damage will result.
(9) Open test valve. Turn steering wheel to the
extreme left and right positions until against the
stops, recording the highest indicated pressure at
each position. Compare pressure gauge readings to
power steering pump specifications. If highest output
pressures are not the same against either stop, the
steering gear is leaking internally and must be
replaced.
SERVICE PROCEDURES
POWER STEERING SYSTEM FLUID LEVEL CHECK
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH ENGINE OFF TO PREVENT INJURY FROM
MOVING PARTS. DO NOT USE AUTOMATIC TRANS-
MISSION FLUID IN THE POWER STEERING SYS-
TEM. DO NOT OVERFILL THE POWER STEERING
SYSTEM.
Wipe reservoir filler cap free of dirt. Then check
fluid level. The dipstick should indicate COLD when
fluid is at normal ambient temperature, approxi-
mately 21ÉC to 27ÉC (70ÉF to 80ÉF). In all pumps add
fluid as necessary, use onlyMopar Power Steering
Fluid, or equivalent. DO NOT USE ANY TYPE
OF AUTOMATIC TRANSMISSION FLUID.
POWER STEERING PUMP INITIAL OPERATION
CAUTION: The fluid level should be checked with
engine off to prevent injury from moving compo-
nents. Use only MoparTPower Steering Fluid. Do
not use automatic transmission fluid. Do not over-
fill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateFULL COLDwhen the
fluid is at normal temperature of approximately 21ÉC
to 27ÉC (70ÉF to 80ÉF).
(1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(2) Start the engine and let run for a few seconds.
Then turn the engine off.
(3) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine.
(4) Raise the front wheels off the ground.
(5) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
stops.
(6) Add power steering fluid if necessary.
(7) Lower the vehicle and turn the steering wheel
slowly from lock to lock.
(8) Stop the engine. Check the fluid level and refill
as required.
(9) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
19 - 10 STEERINGNS
DIAGNOSIS AND TESTING (Continued)

(18) Remove the 3 previously loosened bolts
attaching the front bracket to the power steering
pump and separate the power steering pump from
the front bracket prior to removing the pump from
the vehicle.
(19) The power steering pump is removed from the
vehicle by pulling it out through the exhaust tunnel
area in the floor pan of the vehicle.
INSTALL
(1) Install power steering pump back in vehicle
using the reverse order of its removal through the
exhaust tunnel are of the vehicle.
(2) Install the power steering pump on its cast
mounting bracket and loosely install nut to hold
pump in place (Fig. 9).
(3) Install the front bracket on the power steering
pump and loosely install the 3 mounting bolts (Fig.
10). Then install the nut and bolt attaching the front
bracket to the cast bracket (Fig. 10).
(4) Tighten the 3 power steering pump mounting
bolts (Fig. 10) to a torque of 54 N´m (40 ft. lbs.).
NOTE: Before installing power steering fluid pres-
sure hose on power steering pump, inspect the
O-ring on the pressure hose for damage and
replace if necessary.
(5) Install the power steering fluid pressure line
onto the output fitting of the power steering pump
(Fig. 8). Tighten the pressure line to pump fitting
tube nut to a torque of 31 N´m (275 in. lbs.).
(6) Install the power steering fluid, low pressure
return hose on the power steering pump low pressure
fitting (Fig. 8).Be sure hose clamps are properly
reinstalled.
(7) Install the power steering fluid supply hose
from the power steering fluid reservoir, on the power
steering pump fluid fitting (Fig. 7).Be sure hose is
clear of accessory drive belts all hose clamps
are properly reinstalled.
(8) Install the power steering pump drive belt on
pulley. See Cooling, Group 7 for detailed installation
procedure.
(9) Install the accessory drive splash shield (Fig.
6).
(10) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig. 5).
(11) Install a screw type hose clamp on the power
steering hose to steel tube connection.Be sure hose
clamps are properly reinstalled.Tighten the screw
clamp to a torque of 2 N´m (18 in. lbs.).
CAUTION: The protective heat shield sleeves must
cover the entire rubber hose and hose to tube con-
nection portion of both the power steering fluid
pressure and return hoses (Fig. 5). This is requiredto prevent the overheating of the power steering
hoses.
(12) When used, properly position the protective
heat sleeves on the power steering hoses (Fig. 5).
Then, tie strap the heat sleeves to the power steering
hoses to keep them in their proper position.
(13) Install the exhaust pipe on the exhaust man-
ifold. Install all exhaust system hangers/isolators on
the exhaust system brackets.
(14) Connect the oxygen sensor wiring harness to
the vehicle wiring harness. Install wiring harness
grommet in the floor pan of the vehicle.
(15) Lower vehicle.
(16) Adjust the power steering pump drive belt.
See Cooling, Group 7 for detailed adjustment proce-
dure.
(17) Tighten the top nut and bottom bolt on the
power steering pump front mounting bracket (Fig. 3)
to a torque of 54 N´m (40 ft. lbs.).
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use MoparT, Power
Steering Fluid, or equivalent.
(18) Fill the remote power steering pump fluid res-
ervoir to correct fluid level.
(19) Install cap on power steering fluid reservoir.
(20) Connect the negative battery cable on the
negative battery post.
(21) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
3.0 LITER POWER STEERING PUMP
REMOVE
WARNING: POWER STEERING OIL, ENGINE COM-
PONENTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
(1) Remove the (-) negative battery cable from the
battery and isolate cable.
(2) Remove cap from power steering fluid reser-
voir.
(3) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
NSSTEERING 19 - 13
REMOVAL AND INSTALLATION (Continued)

(13) Remove the power steering fluid return hose
(Fig. 15) from the power steering pump.
(14) Remove the support bracket at the rear of the
power steering pump attaching the pump to the rear
of the engine (Fig. 16).
(15) Remove the 2 bolts mounting the power steer-
ing pump to the alternator/power steering pump and
belt tensioner mounting bracket (Fig. 16).
(16) Remove the power steering pump from its
mounting bracket.
(17) The power steering pump is removed from the
vehicle by pulling it out through the exhaust tunnel
area in the floor pan of the vehicle.
INSTALL
(1) Install power steering pump back in vehicle
using the reverse order of its removal through the
exhaust tunnel are of the vehicle.
(2) Install the power steering pump on its mount-
ing bracket. Install the 2 power steering pumpmounting bolts (Fig. 16). Tighten the power steering
pump mounting bolts to a torque of 54 N´m (40 ft.
lbs.).
(3) Install the support bracket attaching rear of
power steering pump to engine (Fig. 16). Tighten the
nut and bolts to a torque of 54 N´m (40 ft. lbs).
NOTE: Before connecting the power steering pres-
sure line to the power steering pump, inspect the
O-ring on the pressure line for damage and replace
if damaged.
(4) Install the power steering fluid pressure line
onto the output fitting of the power steering pump
(Fig. 15). Tighten the pressure line to pump fitting
tube nut to a torque of 31 N´m (275 in. lbs.).
(5) Install the power steering fluid low pressure
return hose on the power steering pump low pressure
fitting (Fig. 15).Be sure hose clamps are prop-
erly reinstalled and return hose is clear of all
accessory drive belts.
(6) Install the power steering fluid supply hose
from the power steering fluid reservoir, on the power
steering pump fluid fitting (Fig. 15).Be sure all
hose clamps are properly reinstalled.
(7) Install the serpentine drive belt (Fig. 11). See
Cooling, Group 7 for detailed installation procedure.
(8) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig.
13).
(9) Install a screw type hose clamp on the power
steering hose to steel tube connection. Tighten the
screw clamp to a torque of 2 N´m (18 in. lbs.).
CAUTION: The protective heat shield sleeves must
cover the entire rubber hose and hose to tube con-
nection portion of both the power steering fluid
pressure and return hoses (Fig. 13). This is required
to prevent overheating of the power steering hoses.
(10) When used, properly position the protective
heat sleeves on the power steering hoses. Then, tie
strap the heat sleeves to the power steering hoses to
keep them in their proper position.
(11) Install the exhaust pipe on the exhaust man-
ifold. Install all exhaust system hangers/isolators on
the exhaust system brackets.
(12) Connect the oxygen sensor wiring harness to
the vehicle wiring harness. Install wiring harness
grommet in the floor pan of the vehicle.
(13) Install the accessory drive splash shield (Fig.
14).
(14) Lower vehicle.
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use MoparT, Power
Steering Fluid, or equivalent.
Fig. 15 Power Steering Hoses At Power Steering
Pump
Fig. 16 Power Steering Pump Mounting
NSSTEERING 19 - 15
REMOVAL AND INSTALLATION (Continued)