1996 CHRYSLER VOYAGER engine

(4) Remove the serpentine accessory drive belt
from the engine (Fig. 11). See Cooling, Group 7 for
detailed removal procedure.
(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.
(6) Disconnect the oxygen sensor wiring harness
from the vehicle wiring harness. Access to connection
at vehicle wiring harness is through the oxygen sen-
sor wiring harness grommet in the floor pan of the
vehicle.
NOTE: The exhaust system needs to be removed
from the engine to allow for an area to remove the
power steering pump from the vehicle.
(7) Remove the catalytic converter from the
exhaust manifold. Then remove all the exhaust sys-
tem hangers/isolators from the brackets on the
exhaust system.
(8) Move the exhaust system as far rearward and
to the left side of the vehicle as possible (Fig. 12).
(9) Raise the heat sleeve on the power steering
return hose to expose the return hose to steel tube
connection. Remove the hose from the power steering
fluid return line on the front suspension cradle (Fig.
13). Allow the remaining power steering fluid to
drain from the power steering pump and reservoir
through the removed hose.
(10) Remove the accessory drive splash shield
(Fig. 14).
(11) Remove the power steering fluid supply hose
coming from the remote fluid reservoir, from the fit-
ting on the power steering pump (Fig. 15). Drain off
excess power steering fluid from hose.
(12) Remove the power steering fluid pressure line
(Fig. 15) from the power steering pump. Drain excess
power steering fluid from tube.NOTE: If the return hose is not removed from the
power steering pump, it is very difficult to remove
the power steering pump from the vehicle.
Fig. 11 3.0L Serpentine Drive Belt And Routing
Fig. 12 Exhaust Position For Removing Power
Steering Pump
Fig. 13 Power Steering Return Hose At Return Line
Fig. 14 Accessory Drive Splash Shield
19 - 14 STEERINGNS
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)

(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.
3.3/3.8 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.
(4) 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.
(5) Disconnect the oxygen sensor wiring harness
from the vehicle wiring harness. Access to connection
at vehicle wiring harness is through the oxygen sen-
sor wiring harness grommet in the floor pan of the
vehicle.
NOTE: The exhaust system needs to be removed
from the engine to allow for an area to remove the
power steering pump from the vehicle.
(6) Remove the catalytic converter from the
exhaust manifold. Then remove all the exhaust sys-
tem hangers/isolators from the brackets on the
exhaust system.
(7) Move the exhaust system as far rearward and
to the left side of the vehicle as possible (Fig. 17).
(8) Raise the heat sleeve on the power steering
hoses to expose the hose to steel tube connection.
Remove the hose from the power steering fluid
return line on the front suspension cradle (Fig. 18).
Allow the remaining power steering fluid to drain
from the pump and fluid reservoir through the
removed return hose.
(9) Remove the accessory drive splash shield (Fig.
19).
Fig. 17 Exhaust Position For Removing Power
Steering Pump
Fig. 18 Power Steering Return Hose At Return Line
Fig. 19 Accessory Drive Splash Shield
19 - 16 STEERINGNS
REMOVAL AND INSTALLATION (Continued)

(10) Remove the serpentine accessory drive belt
from the engine (Fig. 20). See Cooling, Group 7 for
detailed removal procedure.
(11) Remove the power steering fluid supply hose
coming from the remote fluid reservoir, from the fit-
ting on the power steering pump (Fig. 21). Drain off
excess power steering fluid from hose.
(12) Remove the power steering fluid pressure line
(Fig. 21) from the power steering pump. Drain excess
power steering fluid from tube.
(13) Remove the power steering fluid return hose
(Fig. 21) from the power steering pump. Drain excess
power steering fluid from tube.
(14) Remove the support bracket at the rear of the
power steering pump attaching the pump to the rear
of the engine (Fig. 22).
(15) Remove the 3 bolts mounting the power steer-
ing pump to the alternator/power steering pump and
belt tensioner mounting bracket (Fig. 23).(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 3 power steering pump
mounting bolts (Fig. 23). 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. 22). Tighten the
nut and bolt holding the strut assembly to bracket
and the intake manifold stud to a torque of 54 N´m
(40 ft. lbs).
Fig. 20 Serpentine Drive Belt And Routing
Fig. 21 Power Steering Hoses At Power Steering
Pump
Fig. 22 Power Steering Pump Support Bracket
Fig. 23 Power Steering Pump Mounting Bolts
NSSTEERING 19 - 17
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)

cation and Maintenance section of this service man-
ual, for the required lifting procedure to be used for
this vehicle.
(5) Remove at power steering pump, the power
steering fluid hose coming from the power steering
fluid reservoir. Let the power steering fluid drain out
of the reservoir and hose.
(6) Lower vehicle.
(7) Remove hose clamp attaching the power steer-
ing fluid supply hose to the power steering fluid res-
ervoir (Fig. 24).
(8) Remove the power steering fluid supply hose
from the vehicle. Hose is removed from the top of the
engine compartment.
INSTALL
CAUTION: On V-6 engine applications, the power
steering fluid reservoir to power steering hose must
be routed tightly against the strut tower and parallel
to the dash panel. It must also be routed under the
wiring harness and below the drip tube. This rout-
ing will prevent the power steering fluid supply
hose from coming in contact with the accessory
drive belt.
(1) Install and correctly route the power steering
fluid supply hose from remote fluid reservoir down to
power steering pump.
(2) Install the fluid supply hose onto the power
steering fluid reservoir (Fig. 24). Install the hose
clamp on the fluid supply hose.Be sure hose clamp
is installed past bead on fluid reservoir fitting.
(3) 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.
(4) Install power steering fluid supply hose on
power steering pump. Install the hose clamp on the
fluid supply hose.Be sure hose clamp is installed
past bead on pump fitting.
(5) Lower vehicle.
(6) Install routing clip on power steering fluid sup-
ply hose. Be sure routing clip is installed in a posi-
tion to correctly align with stud in strut tower.
(7) Install routing clip for power steering fluid sup-
ply hose on stud in strut tower (Fig. 25).
(8) Fill the remote fluid reservoir to the proper
level and let the fluid settle for at least two (2) min-
utes.
(9) Start the engine and let run for a few seconds.
Then turn the engine off.
(10) Add fluid if necessary. Repeat the above pro-
cedure until the fluid level remains constant after
running the engine.
(11) Raise the front wheels off the ground.(12) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
stops.
(13) Add power steering fluid if necessary.
(14) Lower the vehicle and turn the steering wheel
slowly from lock to lock.
(15) Stop the engine. Check the fluid level and
refill as required.
(16) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
POWER STEERING FLUID PRESSURE 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 heat sleeve on the power steering
fluid return hose (Fig. 26) to expose the return hose
to steel tube connection. Remove the hose clamp from
the power steering fluid return hose (Fig. 26).
Remove power steering fluid return hose from steel
tube and allow power steering fluid to drain from
pump.
NSSTEERING 19 - 19
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)

REMOTE POWER STEERING FLUID RESERVOIR
REMOVE
(1) Remove the filler cap from remote power steer-
ing fluid reservoir (Fig. 31).
(2) 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.
(3) Remove at power steering pump, the power
steering fluid hose coming from the power steering
fluid reservoir. Let the power steering fluid drain out
of the reservoir and hose.
(4) Lower vehicle.
(5) Remove the fluid supply hose (Fig. 31) from the
remote power steering fluid reservoir.
(6) Remove the 2 mounting screws (Fig. 31)
attaching the remote fluid reservoir to the inner
fender.
(7) Remove remote reservoir from inner fender.
INSTALL
(1) Install remote power steering fluid reservoir on
inner fender, by first inserting tab on reservoir into
hole in inner fender. Then rotate reservoir so mount-
ing tabs are against inner fender.
(2) Install and securely tighten the 2 reservoir
mounting screws (Fig. 31).
CAUTION: The power steering fluid reservoir to
power steering pump supply hose must be routed
tightly against the strut tower and parallel to the
dash panel. It must also be routed under the wiring
harness and below the drip tube. This will prevent
the hose from coming in contact with the accessory
drive belt. The power steering fluid supply hose
must be located in its correct position by clipping it
to the stud in the strut tower (Fig. 32).(3) Install the fluid supply hose onto the power
steering fluid reservoir fitting (Fig. 31). Install the
hose clamp on the fluid supply hose at the fluid res-
ervoir.Be sure hose clamp in installed past bead
on fluid reservoir fitting.
(4) 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.
(5) Install power steering fluid supply hose on
power steering pump. Install the hose clamp on the
fluid supply hose at the power steering pump.Be
sure hose clamp in installed past bead on pump
fitting.
(6) Lower vehicle.
(7) Install routing clip for power steering fluid sup-
ply hose on stud in strut tower (Fig. 32).
(8) Fill the remote fluid reservoir to the proper
level and let the fluid settle for at least two (2) min-
utes.
(9) Start the engine and let run for a few seconds.
Then turn the engine off.
(10) Add fluid if necessary. Repeat the above pro-
cedure until the fluid level remains constant after
running the engine.
(11) Raise the front wheels off the ground.
(12) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
stops.
(13) Add power steering fluid if necessary.
(14) Lower the vehicle and turn the steering wheel
slowly from lock to lock.
(15) Stop the engine. Check the fluid level and
refill as required.
(16) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
Fig. 31 Remote Power Steering Fluid Reservoir
Fig. 32 Power Steering Fluid Hose Routing Clip
19 - 22 STEERINGNS
REMOVAL AND INSTALLATION (Continued)