2001 CHRYSLER VOYAGER Service Manual

hood open battery replacement oil viscosity OBD port horn service

Page 2953 of 4284

CHRYSLER VOYAGER 2001 Service Manual INSTALLATION - PUMP (2.4L ENGINE)
(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 p

INSTALLATION - PUMP (2.4L ENGINE)
(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 (Fig. 7), then install the nut and
bolt attaching the front bracket to the cast bracket
(Fig. 8).Do not fully tighten at this time..
(3) Install the rear nut (Fig. 7).
(4) Install the power steering pump drive belt on
pulley and adjust (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - INSTALLATION).(5) Tighten the two adjustment slot bolts and the
one pivot bolt to 54 N´m (40 ft.lbs.) torque.
(6) Install the accessory drive splash shield.
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.
(7) Install the power steering fluid pressure line
onto the output fitting of the power steering pump
(Fig. 6). Tighten the pressure line to pump fitting
tube nut to a torque of 31 N´m (275 in. lbs.).
(8) Install the power steering fluid low pressure
return hose on the power steering pump low pressure
fitting (Fig. 6).Be sure hose clamps are properly
reinstalled.
(9) Install the power steering fluid supply hose on
the power steering pump fluid fitting.Be sure hose
is clear of accessory drive belts all hose clamps
are properly reinstalled.
(10) When used, properly position the protective
heat sleeve on the power steering return hose. Tie
strap the heat sleeve to the power steering hose to
keep in it's proper position.
(11) Install the exhaust system (Fig. 4). Install all
exhaust system isolators/hangers on the exhaust sys-
tem brackets, then the four bolts and flag nuts (Fig.
3).
(12) Connect the oxygen sensor wiring harness to
the vehicle wiring harness.
(13) Lower vehicle.
(14) Connect the negative battery cable on the
negative battery post.
(15) Perform the POWER STEERING PUMP INI-
TIAL OPERATION procedure to properly fill and
bleed the power steering system. (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE)
(16) Inspect for leaks.
INSTALLATION - PUMP (3.3L/3.8L ENGINE)
(1) Install power steering pump back in vehicle
using the reverse order of its removal through the
engine compartment of the vehicle.
(2) Install the power steering pump on its mount-
ing bracket.
(3) Install the 3 front and 1 rear power steering
pump mounting bolts (Fig. 9). Remember to place
spacer between pump and rear mounting bracket
when installing rear mounting bolt. Tighten the
power steering pump mounting bolts to a torque of
54 N´m (40 ft. lbs.).
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.
Fig. 13 Pulley Installation
1 - POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL
C-4063±A
Fig. 14 Pulley To Pump Shaft Location
1 - PULLEY
2 - PUMP BODY
3 - PUMP SHAFT
4 - HUB
RSPUMP19-29
PUMP (Continued)

Page 2954 of 4284

CHRYSLER VOYAGER 2001 Service Manual (4) Install the power steering fluid pressure line
into the pressure output fitting of the power steering
pump (Fig. 11). Tighten the pressure line to pump fit-
ting tube nut to a torque of 31 N´m (2

(4) Install the power steering fluid pressure line
into the pressure output fitting of the power steering
pump (Fig. 11). Tighten the pressure line to pump fit-
ting 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. 11).Be sure hose clamps are prop-
erly reinstalled.
(6) Raise the vehicle.
(7) Install the routing clip on the engine for the
pressure hose (Fig. 10).
(8) Tighten the pump thru-bolt (Fig. 9). Tighten to
54 N´m (40 ft. lbs.) torque.
(9) Install the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(10) Install the drive belt splash shield.
(11) Lower the vehicle.
(12) Install the wiper module (unit)(Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION).
(13) Connect the negative battery cable on the
negative battery post.
(14) Fill and bleed the power steering system
using the Power Steering Pump Initial Operation
Procedure (Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
(15) Inspect for leaks.
SPECIAL TOOLS
POWER STEERING PUMP
FLUID
STANDARD PROCEDURE - POWER STEERING
FLUID LEVEL CHECKING
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT INJURY
FROM MOVING PARTS.
The fluid level can be read on the exterior of the
power steering fluid reservoir. The fluid level should
be within the ªFILL RANGEº when the fluid is at
normal ambient temperature, approximately 21ÉC to
27ÉC (70ÉF to 80ÉF) (Fig. 15).
Before removing the power steering filler cap, wipe
the reservoir filler cap free of dirt and debris. Do not
overfill the power steering system. Use onlyMopart
Power Steering Fluid (MS-5931)or quivalent.
FLUID COOLER
DESCRIPTION
All models of this vehicle are equipped with a
cooler for the power steering system fluid. The power
steering fluid cooler is located on the front suspen-
sion cradle crossmember reinforcement (Fig. 16).
There are two different size coolers offered depending
on options. There is a standard 6-inch and an 8-inch
for vehicles equipped with the heavy duty cooling
package.
OPERATION
The purpose of the power steering fluid cooler is to
keep the temperature of the power steering system
fluid from rising to a level that would affect the per-
formance of the power steering system.
Installer C-4063B
Puller C-4333
Fig. 15 POWER STEERING FLUID RESERVOIR
19 - 30 PUMPRS
PUMP (Continued)

Page 2955 of 4284

CHRYSLER VOYAGER 2001 Service Manual The cooler used on this vehicle is referred to as a
fluid-to-air type cooler. This means that the air flow
across the tubes (and fines surrounding them) of the
cooler is used to extract the heat from

Page 2956 of 4284

Page 2957 of 4284

CHRYSLER VOYAGER 2001 Service Manual STEERING
TABLE OF CONTENTS
page page
GEAR..................................1PUMP..................................6
GEAR
TABLE OF CONTENTS
page page
GEAR
REMOVAL...............................1INSTALL

Page 2958 of 4284

CHRYSLER VOYAGER 2001 Service Manual (11) Remove the bolts attaching the cradle cross-
member reinforcement to the front suspension cradle
crossmember (Fig. 4). Remove the 2 bolts fastening
the reinforcement and rear of cradle crossmembe

Page 2959 of 4284

CHRYSLER VOYAGER 2001 Service Manual (16) Remove the 3 bolts and nuts mounting the
steering gear to the front suspension cradle.
NOTE: The next step must be done to allow the
removal of the steering gear from the front suspen-
sion cradl

Page 2960 of 4284

CHRYSLER VOYAGER 2001 Service Manual INSTALLATION - RHD GEAR
(1) Install the steering gear up in the front sus-
pension cradle crossmember, leaving room to install
intermediate coupler.
(2) Start the roll pin into the intermediate couple

INSTALLATION - RHD GEAR
(1) Install the steering gear up in the front sus-
pension cradle crossmember, leaving room to install
intermediate coupler.
(2) Start the roll pin into the intermediate coupler
before installing coupler on steering gear shaft. Start
roll pin into coupler, using a hammer and tapping it
into the coupler. Then install the intermediate cou-
pler on the shaft of the steering gear.
(3) Install Remover/Installer Special Tool 6831A
through the center of the roll pin, securing it with
the knurled nut (Fig. 8). Hold threaded rod station-
ary while turning nut. This will pull the roll pin into
the intermediate coupler.
(4) Install power steering gear on the front suspen-
sion cradle. Install the 3 steering gear mounting
bolts and nuts. Tighten the 3 steering gear to sus-
pension cradle mounting bolts to a torque of 183 N´m
(135 ft. lbs.).
CAUTION: Proper torque on the steering gear to
suspension cradle mounting bolts is very impor-
tant.
(5) Install the heat shield on the steering gear
(Fig. 5).
(6) Attach the power steering fluid pressure and
return hoses to the proper fittings on the steering
gear (Fig. 5). Do not fully tighten the fittings at this
time.
(7) Install the routing clamp with the bolt securing
the power steering fluid hoses to the rear of the cra-
dle crossmember (Fig. 6).(8) Using a crowfoot wrench on a torque wrench,
tighten the power steering fluid hose tube nuts at the
gear to a torque of 31 N´m (275 in. lbs.).
(9) Install tie rod end into steering knuckle. Start
tie rod end to steering knuckle attaching nut onto
stud of tie rod end. While holding stud of tie rod end
stationary using a socket (Fig. 2), tighten tie rod end
to steering knuckle attaching nut. Then using a
crowfoot and socket (Fig. 9), tighten the tie rod end
attaching nut to a torque of 75 N´m (55 ft. lbs.).
(10) If the vehicle is equipped with All-Wheel-
Drive, install the power transfer unit (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - INSTALLATION).
CAUTION: Proper torque on the cradle reinforce-
ment to suspension cradle mounting bolts is very
important.
(11) Install the reinforcement on the front suspen-
sion cradle crossmember and install the bolts attach-
ing the reinforcement to the cradle crossmember
(Fig. 4). Tighten the M-14 size bolts to a torque of
163 N´m (120 ft. lbs.). Tighten the M-12 size bolts to
a torque of 108 N´m (80 ft. lbs.).
(12) Install the lower control arm rear bushing
retainer bolts through reinforcement on each side of
each lower control arm rear bushing. Tighten bolts to
a torque of 61 N´m (45 ft. lbs.).
(13) Install the two bolts and bushings attaching
the reinforcement and rear of cradle crossmember to
body of vehicle (Fig. 4). Tighten bolts to a torque of
163 N´m (120 ft. lbs.).
Fig. 8 Installing Roll Pin In Intermediate Coupler
1 - INTERMEDIATE COUPLER
2 - SUSPENSION CRADLE
3 - KNURLED NUT
4 - ROLL PIN
5 - STEERING GEAR
Fig. 9 Torquing Tie Rod End Attaching Nut
1 - STEERING KNUCKLE
2 - TIE ROD END
3 - CROWFOOT
4 - SOCKET
5 - TORQUE WRENCH
19a - 4 GEARRG
GEAR (Continued)

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