1996 CHRYSLER VOYAGER tire type

(9) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(10) Spread the strands of the wire apart on each
part of the exposed wires.
(11) Push the two ends of wire together until the
strands of wire are close to the insulation.
(12) Twist the wires together.
(13) Solder the connection together using rosin
core type solder only.Do not use acid core solder.
(14) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(15) Insert the repaired wire into the connector.
(16) Install the connector locking wedge, if
required, and reconnect the connector to its mating
half/component.
(17) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(18) Connect battery, and test all affected systems.
DIODE REPLACEMENT
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 22).
(4) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(5) Install the new diode in the harness, making
sure current flow is correct. If necessary refer to the
appropriate wiring diagram for current flow.
(6) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(7) Tape the diode to the harness using electrical
tape making, sure the diode is completely sealed
from the elements.
(8)
Re-connect the battery, and test affected systems.
SPECIAL TOOLS
WIRING/TERMINAL
Fig. 22 Diode Identification
Probing Tool Package 6807
Terminal Pick 6680
Terminal Removing Tool 6932
Terminal Removing Tool 6934
8W - 01 - 14 8W-01 GENERAL INFORMATIONNS/GS
SERVICE PROCEDURES (Continued)

leaks are not present. The component should be
replaced immediately if there is any evidence of deg-
radation that could result in failure.
Never attempt to repair a plastic fuel line/tube or a
quick±connect fitting. Replace complete line/tube as
necessary.
Avoid contact of any fuel tubes/hoses with other
vehicle components that could cause abrasions or
scuffing. Be sure that the fuel lines/tubes are prop-
erly routed to prevent pinching and to avoid heat
sources.
The lines/tubes/hoses are of a special construction.
If it is necessary to replace these lines/tubes/hoses,
use only original equipment type.
The hose clamps used to secure the rubber hoses
are of a special rolled edge construction. This con-
struction is used to prevent the edge of the clamp
from cutting into the hose. Only these rolled edge
type clamps may be used in this system. All other
types of clamps may cut into the hoses and cause
fuel leaks.
Where a rubber hose is joined to a metal tube
(staked), do not attempt to repair. Replace entire
line/tube assembly.
Use new original equipment type hose clamps.
Tighten hose clamps to 2 N´m (20 in. lbs.) torque.
QUICK-CONNECT FITTINGSÐLOW PRESSURE
TYPE
Different types of quick-connect fittings are used to
attach various fuel system components. These are: a
single-tab type, a two-tab type or a plastic retainer
ring type (Fig. 8). Refer to Quick-Connect Fittings in
the Removal/Installation section for more informa-
tion.
CAUTION: The interior components (o-rings, spac-
ers) of quick-connect fitting are not serviced sepa-
rately, but new pull tabs are available for some
types. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
HIGH-PRESSURE FUEL LINES
CAUTION: The high±pressure fuel lines must be
held securely in place in their holders. The lines
cannot contact each other or other components. Do
not attempt to weld high±pressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of high±pressure
fuel line is necessary.
High±pressure fuel lines deliver fuel under pres-
sure of up to approximately 45,000 kPa (6526 PSI)
from the injection pump to the fuel injectors. Thelines expand and contract from the high±pressure
fuel pulses generated during the injection process. All
high±pressure fuel lines are of the same length and
inside diameter. Correct high±pressure fuel line
usage and installation is critical to smooth engine
operation.
WARNING: USE EXTREME CAUTION WHEN
INSPECTING FOR HIGH±PRESSURE FUEL LEAKS.
INSPECT FOR HIGH±PRESSURE FUEL LEAKS WITH
A SHEET OF CARDBOARD. HIGH FUEL INJECTION
PRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
FUEL DRAIN TUBES
These rubber tubes are low±pressure type.
Some excess fuel is continually vented from the
fuel injection pump. During injection, a small amount
of fuel flows past the injector nozzle and is not
injected into the combustion chamber. This fuel
drains into the fuel drain tubes (Fig. 9) and back to
the tee banjo fitting, which is connected to the same
line as the overflow valve, which allows a variable
quantity to return to the fuel tank. The overflow
valve is calibrated to open at a preset pressure.
Excess fuel not required by the pump to maintain the
minimum pump cavity pressure is then returned
through the overflow valve and on to the fuel tank
through the fuel return line.
Fig. 8 Plastic Retainer Ring-Type Fitting
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 7
DESCRIPTION AND OPERATION (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)

NOTE: Before installing power steering pressure
hose on power steering pump, inspect the O-ring
on the power steering pressure hose for damage
and replace if required.
(4) Install the power steering fluid pressure line
onto the output fitting of the power steering pump
(Fig. 21). 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. 21).Be sure hose clamps are prop-
erly reinstalled.
(6) Install the power steering fluid supply hose
from the power steering fluid reservoir, on the power
steering pump fluid fitting (Fig. 21).Be sure hose is
clear of accessory drive belts and all hose
clamps are properly reinstalled.
(7) Install the serpentine drive belt (Fig. 20). 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.
18).
(9) 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. 18). This is required
to keep the power steering hoses from becoming
overheated.
(10) When used, properly position the protective
heat sleeves on the power steering hoses (Fig. 18).
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.
19).
(14) Lower vehicle.
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use MoparT, Power
Steering Fluid, or equivalent.
(15) Fill the remote power steering pump fluid res-
ervoir to correct fluid level.
(16) Install cap on power steering fluid reservoir.(17) Connect the negative battery cable on the
negative battery post.
(18) 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.
POWER STEERING FLUID RESERVOIR TO PUMP
SUPPLY HOSE
REMOVE
(1) Remove the filler cap from remote power steer-
ing fluid reservoir (Fig. 24).
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) Remove power steering fluid supply hose rout-
ing clip (Fig. 25) from stud in strut tower.
(4) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
Fig. 24 Fluid Supply Hose At Power Steering Fluid
Reservoir
Fig. 25 Power Steering Fluid Hose Routing Clip
19 - 18 STEERINGNS
REMOVAL AND INSTALLATION (Continued)

(6) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig.
26).
(7) 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 sleeves must cover
the entire rubber hose and hose to tube connection
portion of both the power steering fluid pressure
and return hoses (Fig. 26).
(8) 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.
(9) After hoses are installed and power steering
system is filled with fluid and cap is installed on res-
ervoir. Start the engine and check for leaks. (See
Pump Installation).
POWER STEERING FLUID RETURN HOSE
Service all power steering hoses with vehicle raised
on hoist. Cap all open ends of hoses, power steering
pump fittings and steering gear ports to prevent
entry of foreign material into the components.
WARNING: POWER STEERING OIL, ENGINE
PARTS 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.
For part reference and part location for the vehicle
that is being serviced, refer to the following figure
numbers. These show the hose bracket locations,
hose routings and fitting locations by the engine
application of the vehicle. Use these figure numbers
when referring to the removal or installation proce-
dures for the power steering hoses listed below.
REMOVE
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) Raise vehicle See Hoisting, Group 0. Put oil
drain pan under vehicle to catch power steering fluid.
(4) Raise the insulating heat sleeve on the power
steering hoses to expose the hose to steel tube con-
nection. Remove hose clamp where rubber portion of
power steering fluid return hose attaches to steel
tube on suspension cradle (Fig. 30). Remove rubber
hose from steel tube and allow power steering fluid
to drain from pump.(5) Remove the power steering fluid return hose
from the power steering pump return hose fitting.
INSTALL
(1) Using a lint free towel, wipe clean the open
power steering hose ends and power steering pump
fitting.
(2) Attach the power steering return hose to the
fitting on the power steering pump. Route hose
smoothly avoiding tight bends or kinking. Hose must
remain away from the exhaust system and not come
in contact with any unfriendly surfaces of the vehi-
cle.
(3) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig.
30).
(4) 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. 30). This is to pre-
vent overheating of the power steering fluid hoses.
(5) When used, position the protective heat sleeves
on the power steering hoses so they cover the connec-
tion to the power steering pump. Then, tie strap the
heat sleeves to the power steering hoses to keep
them in their proper position.
(6) After hoses are installed and power steering
system is filled with fluid and cap is installed on res-
ervoir. Start the engine and check for leaks. (See
Pump Installation).
Fig. 30 Power Steering Return Hose At Steel Tube
NSSTEERING 19 - 21
REMOVAL AND INSTALLATION (Continued)

(6) Remove the pressure fitting/flow control valve
from the power steering pump and remove and dis-
card the O-Ring seal.
ASSEMBLE
(1) Install a new O-Ring seal on the pressure fit-
ting/flow control valve, and wet the O-Ring with
clean fresh power steering fluid.
(2) Install the pressure fitting/flow control valve in
the power steering pump. Tighten the pressure fit-
ting/flow control valve to a torque of 75 N´m (55 ft.
lbs.).
CAUTION: When tightening and torquing the pres-
sure hose at the power steering pump, the hose
should be rotated against the fluid return hose fit-
ting on the pump.(3) Install the power steering fluid pressure hose
in the pressure fitting/flow control valve (Fig. 37).
Tighten the tube nut to a torque of 34 N´m (25 ft.
lbs.)
(4) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig.
36).
(5) 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. 36). This is required
to keep the power steering hoses from becoming
overheated.
(6) When used, properly position the protective
heat sleeves (Fig. 36) on the power steering hoses.
Then, tie strap the heat sleeves to the power steering
hoses to keep them in their proper position.
(7) Fill the power steering system with fluid, bleed
air from system and check that power steering fluid
is at correct level.
SPECIFICATIONS
POWER STEERING SYSTEM SPECIFICATIONS
Flow At 1500 RPM And Minimum Pressure.5.0 to 7.0
Liters/Min (1.3 to 1.9 GPM)
Control Valve Pressure Relief. 9653 to 10342 kPa (1400
to 1500psi)
POWER STEERING PUMP FASTENER TORQUE
SPECIFICATIONS
DESCRIPTION TORQUE
POWER STEERING PUMP:
Flow Control Valve Fitting. . . .75 N´m (55 ft. lbs.)
Mounting Bolts.............54N´m(40ft.lbs.)
Rear Bracket To Engine
Mounting Bolts.............54N´m(40ft.lbs.)
POWER STEERING FLUID HOSES:
Hose Tube Nuts.............34N´m(25ft.lbs.)
Routing Bracket To
Suspension Cradle..........28N´m(21ft.lbs.)
Fig. 36 Return Hose At Steel Tube
Fig. 37 Pressure Hose Connection To Power
Steering Pump
19 - 24 STEERINGNS
DISASSEMBLY AND ASSEMBLY (Continued)

(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) With the ignition key in the locked position
turn the steering wheel to the left until the steering
wheel is in the locked position.
(4) With the vehicle on the ground, disconnect the
steering column shaft coupler from the steering gear
intermediate coupler (Fig. 3).
(5) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this service man-
ual, for the required lifting procedure to be used for
this vehicle.
(6) Remove the front tires.
(7) Raise the heat sleeve (Fig. 4) on the power
steering return hose to expose the return hose to
steel tube connection. Remove the return hose from
the metal tube of the power steering fluid return line
(Fig. 4). Then allow the remaining power steering
fluid to drain from the system through the hose and
metal tube.
(8) Remove nut attaching outer tie rod end to
steering knuckle (Fig. 5).Nut is to be removed
from tie rod end using the following procedure,
hold tie rod end stud with a 11/32 socket while
loosening and removing nut with wrench.
(9) Remove both tie rod ends from steering knuck-
les, using Puller Special Tool MB-990635 or
MB-991113 (Fig. 6).
Fig. 3 Steering Column Shaft To Intermediate Shaft
Attachment
Fig. 4 Power Steering Fluid Return Hose
Connection
Fig. 5 Removing/Installing Tie Rod End Attaching
Nut
Fig. 6 Tie Rod End Removal From Steering Knuckle
19 - 28 STEERINGNS
REMOVAL AND INSTALLATION (Continued)