2002 CHRYSLER VOYAGER power steering fluid

(7) Disconnect the manifold absolute pressure
(MAP) sensor electrical connector.
(8) Disconnect the vapor purge vacuum hose from
throttle body.
(9) Disconnect the PCV hose (Fig. 120).
(10) Remove the power steering reservoir attach-
ing bolts and only loosen the nut (Fig. 121). Lift res-
ervoir up to disengage lower mount from stud. Set
reservoir aside.Do notdisconnect hose.
(11) Disconnect the brake booster and leak detec-
tion pump (LDP) hoses from intake manifold (Fig.
122).
(12) Remove intake manifold bolts and remove the
manifold (Fig. 123).
(13) Cover the lower intake manifold with a suit-
able cover while the upper manifold is removed.
(14) Clean and inspect the upper intake manifold
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - CLEANING) and (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSPECTION).
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
Fig. 120 PCV & HOSE
1 - HOSE - PCV
2 - P C V VA LV E
Fig. 121 POWER STEERING FLUID RESERVOIR
1 - POWER STEERING RESERVOIR
2 - BOLT - RESERVOIR TO MANIFOLD
3 - NUT - RESERVOIR TO COIL BRACKET
Fig. 122 BRAKE BOOSTER & LDP VACUUM HOSES
1 - LDP & SPEED CONTROL VACUUM HOSE
2 - BRAKE BOOSTER VACUUM HOSE
3 - MAP SENSOR
9 - 148 ENGINE 3.3/3.8LRS
INTAKE MANIFOLD - UPPER (Continued)
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(9) Remove power steering reservoir hose from
power steering pump and drain power steering fluid
(Fig. 4).
(10) Disconnect high pressure line at pump (Fig.
4).
(11) Disconnect power steering pump return hose
clamp (Fig. 4).
(12) Remove power steering return line retaining
clamp (Fig. 4).
(13) Remove power steering line clamps from oil
pan (Fig. 4).
(14) Remove power steering pump reservoir and
bracket (Fig. 4).(15) Drain coolant system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(16) Remove coolant pressure tank (Fig. 5).
Fig. 4 RESERVOIR AND HOSES - 2.5L DIESEL
1 - POWER STEERING FLUID RESERVOIR
2 - RESERVOIR BRACKET
3 - SUPPLY HOSE BRACKET
4 - RETURN HOSE FROM GEAR
5 - ROUTING CLIP
6 - PRESSURE HOSE TO GEAR
7 - SUPPLY HOSE (PUMP END)
8 - PRESSURE HOSE (PUMP END)
9 - SUPPLY HOSE
10 - RETURN HOSE
Fig. 5 COOLANT RECOVERY PRESSURE
CONTAINER LOCATION
1 - PRESSURE/VENT CAP
2 - BRAKE MASTER CYLINDER
3 - BATTERY
4 - BATTERY SHIELD
5 - COOLANT RECOVERY PRESSURE CONTAINER RETAING
CLIP
6 - ENGINE COVER
7 - COOLANT RECOVERY PRESSURE CONTAINER
9a - 4 ENGINERG
ENGINE 2.5L TURBO DIESEL (Continued)
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INSTALLATION
INSTALLATION - 2.5L TURBO DIESEL ENGINE
(1) Reassembly engine and transmission assembly
and install on engine cradle.
(2) Position engine and cradle assembly under
vehicle.
(3) Slowly lower the vehicle down over the engine
and cradle assembly.
(4) Install right engine mount bolts. Torque to
54N´m (40 ft. lbs.)
(5) Install left engine mount through bolt. Torque
to 75N´m (55 ft. lbs.)
(6) Raise vehicle and engine from engine cradle.
(7) Attach front engine mount bracket to lower
radiator support. Torque to 54N´m (40 ft. lbs.)
(8) Connect cabin heater coolant hose.
(9) Connect exhaust pipe to the turbocharger
downpipe flange. Torque to 28 N´m (250 in. lbs.)
(10) Connect reverse lamp electrical connector at
transmission.
(11) Connect both shifter cables (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL/GEAR
SHIFT CABLE - INSTALLATION).
(12) Connect the clutch slave cylinder quick dis-
connect connector (RHD only)(Refer to 6 - CLUTCH/
SLAVE CYLINDER - INSTALLATION).
(13) Install engine harness into bracket on trans-
mission.
(14) Lower vehicle.
(15) Connect fuel supply and return lines.
(16) Connect A/C lines to A/C compressor. Torque
to 23N´m (17 ft. lbs.)
(17) Route engine wiring harnes to proper location.
(18) Connect engine harness ground cables to
engine block
(19) Connect starter solenoid electrical connector
and battery feed wire to starter. Torque to 10N´m (90
in. lbs.)
(20) Connect A/C compressor, injection pump, glow
plugs, and coolant temperature sensor electrical con-
nectors.
(21) Connect generator electrical connector. Torque
to 9N´m (75 in. lbs.)
(22) Connect the fuel injector, fuel pressure sensor,
boost pressure/intake air temp sensor, cam sensor,
and egr solenoid electrical connectors (Fig. 8).
(23) Connect egr solenoid vacuum supply line to
brake boost vacuum supply line.(24) Connect brake booster vacuum supply line.
(25) Connect heater core return hose to coolant
pipe.
(26) Connect lower radiator hose to engine (Fig. 7).
(27) Install charger air cooler inlet hose (Fig. 6).
(28) Install charge air cooler outlet hose (Fig. 6).
(29) Connect upper radiator hose to engine (Fig.
7).
(30) Install battery shield.
(31) Install coolant reserve pressure container
(Refer to 7 - COOLING/ENGINE/COOLANT RECOV-
ERY PRESS CONTAINER - INSTALLATION).
(32) Install power steering reservoir and bracket
(Fig. 4).
(33) Raise vehicle
(34) Connect oil pressure sensor, oil temperature
sensor, engine speed sensor, and vehicle speed sensor
electrical connector (Fig. 9).
(35) Install suspension cradle in vehicle (Refer to
13 - FRAME & BUMPERS/FRAME/ENGINE CRA-
DLE CROSSMEMBER - INSTALLATION).
(36) Install both axle shaft assemblies (Refer to 3 -
DIFFERENTIAL & DRIVELINE/HALF SHAFT -
INSTALLATION).
(37) Connect the power steering supply, pressure,
and return lines to power steering pump (Fig. 4).
(38) Install the power steering line brackets on oil
pan (Fig. 4).
(39) Install lower splash shield and side panels.
(40) Install both front wheel and tire assemblies.
(41) Lower vehicle.
(42) Install air cleaner housing, MAF sensor, and
air intake tube assembly (Fig. 3).
(43) Refill transmission to proper level (Refer to 21
- TRANSMISSION/TRANSAXLE/MANUAL/FLUID -
STANDARD PROCEDURE).
(44) Refill engine coolant (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(45) Recharge A/C system (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/REFRIGER-
ANT - STANDARD PROCEDURE) .
(46) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION) (Fig. 2).
(47) Connect negative battery cable.
INSTALLATION - ENGINE COVER
(1) Install engine cover on engine.
(2) Install the engine cover mounting bolts (Fig.
10).
RGENGINE9a-7
ENGINE 2.5L TURBO DIESEL (Continued)
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REMOVAL
The front cradle crossmember must be installed in
the design location to achieve proper front end sus-
pension alignment. If the cradle crossmember is
removed without applying reference marks on the
frame rails, align the cradle crossmember according
to the dimensions provided in this group.
NOTE: If the caged nuts in the frame rails become
damaged and cannot be reused, a replacement nut
can be obtained through MoparT.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove steering column lower cover from
instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/STEERING COLUMN OPENING
COVER - REMOVAL).
(3) Remove steering column cover backing plate
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN COVER BACKING PLATE - REMOV-
AL).
(4) Position steering so front wheels are straight
ahead.
CAUTION: Do not rotate steering wheel after disen-
gaging lower coupling from steering gear, damage
to air bag clock spring can result.
(5) Remove clinch bolt attaching steering column
coupling to steering gear shaft (Fig. 10).(6) Remove steering column coupling from tele-
scoping steering gear shaft.
(7) Hoist vehicle and support on safety stands.
(8) Position a drain pan under power steering
pump and oil return hose coupling.
(9) Using a hose pinch-off pliers (C-4390), pinch
power steering oil return hose off between the cross-
member coupling and the pump.
(10) Loosen hose clamp at the cradle crossmember
coupling.
(11) Disconnect return hose from metal tube.
(12) While holding pressure relief valve nut on
back of power steering pump, Remove flare nut
attaching high pressure hose to back of pump.
(13) Remove high pressure hose from pump.
(14) Allow power steering fluid to drain into pan.
(15) Remove bolts attaching anti-lock brake sensor
leads to cradle crossmember.
(16) Position anti-lock brake leads out of the way.
(17) Disconnect stabilizer bar links from ends of
stabilizer bar.
(18) Disconnect lower ball joints from lower steer-
ing knuckles (Refer to 2 - SUSPENSION/FRONT/
LOWER BALL JOINT - REMOVAL).
(19) Remove the rear engine mount heat shield
(Fig. 11).
(20) Remove through bolt attaching rear engine
mount to cradle crossmember (Fig. 12).
(21) Using paint or grease pencil, mark outline of
cradle crossmember on frame rails to aid installation.
(22) Support cradle crossmember on suitable lift-
ing device (Fig. 14).
(23) Remove bolts attaching crossmember to front
frame rails (Fig. 13).
Fig. 10 STEERING COUPLING
1 - STEERING SHAFT BOOT
2 - STEERING SHAFT
3 - CROSSMEMBER
4 - STEERING GEAR
5 - MOUNT
6 - TRANSAXLE
Fig. 11 REAR MOUNT HEAT SHIELD
1 - BOLT
2 - HEAT SHIELD
3 - CLIP
4 - REAR ENGINE MOUNT
13 - 10 FRAME & BUMPERSRS
FRONT CRADLE CROSSMEMBER (Continued)
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STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION - POWER STEERING SYSTEM . . 1
OPERATION - POWER STEERING SYSTEM . . . 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER
STEERING SYSTEM FLOW AND
PRESSURE TEST......................1
DIAGNOSIS AND TESTING - STEERING
SYSTEM DIAGNOSIS CHARTS............3SPECIFICATIONS
POWER STEERING FASTENER TORQUE . . . 9
SPECIAL TOOLS
POWER STEERING....................9
COLUMN..............................10
GEAR.................................26
PUMP.................................36
STEERING
DESCRIPTION - POWER STEERING SYSTEM
This vehicle comes with power steering as stan-
dard equipment. The power steering system consists
of these major components:
²POWER STEERING PUMP
²POWER STEERING GEAR
²POWER STEERING FLUID
²POWER STEERING FLUID COOLER
²POWER STEERING FLUID RESERVOIR
²POWER STEERING FLUID SUPPLY HOSE
²POWER STEERING FLUID PRESSURE HOSE
²POWER STEERING FLUID RETURN HOSE
For information on the first two components, refer
to their respective sections within this service man-
ual group. Information on all other components can
be found in POWER STEERING PUMP.
OPERATION - POWER STEERING SYSTEM
Turning of the steering wheel is converted into lin-
ear (side-to-side) travel through the meshing of the
helical pinion teeth with the rack teeth within the
steering gear. The lateral travel pushes and pulls the
tie rods to change the direction of the vehicle's front
wheels.
Power assist steering is provided by a belt driven
rotary type pump. It directs fluid through power
steering fluid hoses to the power steering gear where
it is used to assist the driver's turning effort.
Manual steering control of the vehicle can be main-
tained if power steering assist is lost. However,
under this condition, steering effort is significantly
increased.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER STEERING
SYSTEM FLOW AND PRESSURE TEST
ALL ENGINES
The following procedure is to be used to test the
operation of the power steering system on this vehi-
cle. This test will provide the flow rate of the power
steering pump along with the maximum relief pres-
sure. This test is to be performed to determine if the
power steering pump or power steering gear is not
functioning properly. The following flow and pressure
test is performed using the Power Steering Analyzer
Kit, Special Tool 6815 (Fig. 1), hoses, Special Tools
6905 and 6959, and fittings from adapter kit, Special
Tool 6893.
Fig. 1 Power Steering Analyzer With Hoses Installed
1 - OUTLET
2 - SPECIAL TOOL 6815
3 - INLET
RSSTEERING19-1
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Assemble hoses on Power Steering Analyzer, Spe-
cial Tool 6815, as shown. Install Pressure Hose, Spe-
cial Tool 6905 (in 6893 kit), in the inlet fitting on
Power Steering Analyzer. Install Pressure Hose, Spe-
cial Tool 6713 (in 6815 kit) on Pressure Hose, Special
Tool 6905. Install Pressure Hose, Special Tool 6959,
in the outlet fitting on Power Steering Analyzer.
Install the following adapters from Adapter Set,
Special Tool 6893 (Fig. 2), on the analyzer hose ends:
Install Adapter Fitting, Special Tool 6844, on Pres-
sure Hose, Special Tool 6713. Install Adapter Fitting,
Special Tool 6826, on Pressure Hose, Special Tool
6959.
CAUTION: To prevent personal injury, safety gog-
gles should be worn at all times when performing
any test procedures on the power steering pump or
power steering gear.
The following procedure is to be used to test the
operation of the power steering system on the vehi-
cle.
(1) Check belt tension and adjust as necessary.
(2) Disconnect the power steering fluid pressure
hose from the power steering pump (Fig. 3) (Fig. 4).
(3) Connect Adapter Fitting, Special Tool 6844,
attached to pressure hose from inlet (gauge end) of
Power Steering Analyzer to the pressure fitting on
the power steering pump.
(4) Connect vehicle power steering fluid pressure
hose to Adapter Fitting, Special Tool 6826, which
should be already installed in the outlet hose (valve
end) of Power Steering Analyzer.NOTE: During the next few steps, do not steer vehi-
cle as air will be forced into the steering gear.
(5) Completely open valve on Power Steering Ana-
lyzer.
Fig. 2 Power Steering Analyzer Adapters 6893
Fig. 3 Pressure Hose Connection To Power Steering
Pump - 2.4L Engine
1 - POWER STEERING FLUID RETURN HOSE
2 - POWER STEERING PUMP
3 - POWER STEERING FLUID PRESSURE HOSE
Fig. 4 Supply & Pressure Hoses At Pump - 3.3L/3.8L
Engine
1 - PRESSURE HOSE AND FITTING
2 - SUPPLY HOSE AND CLAMP
3 - POWER STEERING PUMP
19 - 2 STEERINGRS
STEERING (Continued)
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(6) Start engine and let idle just long enough to
circulate power steering fluid through the analyzer
and hoses. Shut off engine.
(7) Check power steering fluid level and add fluid
as necessary. Start engine again and let idle until the
air is out of the fluid.
(8) Gauge should read below 300 psi (2068 kPa). If
above, inspect the hoses for restrictions and repair as
necessary. The initial pressure should be in the range
of 100-275 psi (689-1896 kPa) depending on fluid
temperature. The flow meter should read above 1.5
GPM.
CAUTION: The following test procedure involves
testing maximum pump pressure output and flow
control valve operation. Do not leave valve closed
for more than four seconds as the pump could be
damaged.
NOTE: Power steering pump maximum pressure for
2.4L engines is 1,200 ± 1,350 psi (8,274 ± 9,308
kPa). Power steering pump maximum pressure for
all other engines is 1,400 ± 1,500 psi (9,653 ± 10,342
kPa).
(9) Close analyzer valve fully three times and
record highest pressure indicated each time. All three
readings must be within specifications. If any of the
three power steering pump pressures are above orbelow specifications, replace pump. (Refer to 19 -
STEERING/PUMP - REMOVAL)
CAUTION: Do not force the steering to operate
against the stops for more than 4 seconds at a time
because pump damage can result.
(10) Once the pump has been verified as working
correctly, completely open the valve on the Power
Steering Analyzer. Turn the steering wheel to the
extreme left until the stop in the steering gear is
met. Hold it there for 2±4 seconds, then release it.
Now turn the steering wheel to the right until the
right stop is met. Hold it there for 2±4 seconds, then
release it. Record the stabilized pressure at each
position. Compare the recorded readings to the spec-
ifications. If the output pressures are not within 100
psi (689 kPa) of one another against either stop or
are below specifications, the steering gear is leaking
internally and must be replaced. (Refer to 19 -
STEERING/GEAR - REMOVAL)
DIAGNOSIS AND TESTING - STEERING
SYSTEM DIAGNOSIS CHARTS
NOTE: There are three diagnosis charts following
that cover POWER STEERING NOISE, STEERING
WHEEL FEEL, and POWER STEERING FLUID.
POWER STEERING NOISE
CONDITION POSSIBLE CAUSES CORRECTION
OBJECTIONABLE HISS
OR WHISTLE*1. Damaged or mispositioned
steering column shaft/coupling dash
panel seal.1. Reposition or replace steering
column shaft/coupling dash panel seal.
2. Noisy valve in power steering
gear.2. Replace power steering gear.
3. Mis-routed power steering hose. 3. Check routing of power steering
hoses. Ensure hoses do not come in
unwanted contact with other
components and objects.
RATTLE OR EXCESSIVE
CLUNK**1. Power steering gear loose on front
suspension crossmember.1. Inspect power steering gear
mounting bolts. Replace as necessary.
Tighten to the specified torque.
2. Front suspension crossmember
mounting fasteners loose at frame.2. Tighten the front suspension
crossmember mounting fasteners to the
specified torque.
3. Loose tie rod (outer or inner). 3. Check tie rod pivot points for wear.
Replace worn/loose parts as required.
RSSTEERING19-3
STEERING (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
4. Loose lower control arm mounting
bolts at front suspension
crossmember.4. Tighten control arm mounting bolts to
the specified torques.
5. Lower control arm pivot bushing
worn.5. Replace lower control arm pivot
bushing.
6. Loose strut assembly mounting
fasteners at tower or knuckle.6. Tighten strut assembly fasteners to
the specified torque.
7. Power steering fluid hose touching
the body of the vehicle.7. Adjust hose to proper position by
loosening, repositioning, and tightening
attachments to specified torque. Do not
bend tubing.
8. Internal power steering gear
noise.8. Replace power steering gear.
9. Damaged front suspension
crossmember.9. Replace front suspension
crossmember.
10. Stabilizer bar link ball joints
worn.10. Replace stabilizer bar link.
11. Lug nuts loose. 11. Tighten lug nuts to specifications.
12. Excessive Wheel bearing
free-play.12. Verify correct driveshaft hub nut
torque. Replace bearing if torque is
okay.
POPPING NOISE 1. Worn outer tie rod. 1. Check ball joint for free-play;
Replace outer tie rod.
2. Loose inner tie rod. 2. Replace power steering gear.
CHIRP OR SQUEAL
(POWER STEERING
PUMP)1. Loose power steering pump drive
belt.1. Check and adjust power steering
pump drive belt to specifications or
replace automatic tensioner where
applicable. Replace belt if worn or
glazed.
2. Malfuctioning belt auto-tensioner 2. Replace belt auto-tensioner.
WHINE, GROWL, MOAN
OR GROAN (POWER
STEERING PUMP)***1. Low fluid level. 1. Fill power steering fluid reservoir to
proper level and check for leaks (make
sure all air is bled from the system
fluid).
2. Power steering hose touching
vehicle body or frame.2. Adjust hose to proper position by
loosening, repositioning, and tightening
fitting to specified torque. Do not bend
tubing. Replace hose if damaged.
3. Extreme wear of power steering
pump internal components.3. Replace power steering pump and
flush system as necessary.
4. Extremely low ambient
temperature.4. Some noise can be expected, but will
go away as vehicle warms. Replace
pump if noise is excessive.
SUCKING AIR SOUND 1. Loose clamp on power steering
fluid return hose.1. Tighten or replace hose clamp.
2. Missing O-Ring on power steering
hose connection.2. Inspect connection and replace
O-Ring as required.
19 - 4 STEERINGRS
STEERING (Continued)
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