2004 CHRYSLER VOYAGER Service Manual

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Page 1585 of 2585

CHRYSLER VOYAGER 2004 Service Manual (17) Remove the 3 bolts attaching the front
bracket to the power steering pump and separate the
power steering pump from the front bracket.
(18) If the power steering pump pulley needs to be
transferr

Page 1586 of 2585

CHRYSLER VOYAGER 2004 Service Manual (3) Using a siphon pump, remove as much power
steering fluid as possible from the fluid reservoir.
(4) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(5) Remov

Page 1587 of 2585

CHRYSLER VOYAGER 2004 Service Manual (1) Install the pulley with Installer C-4063 (Fig.
15). Do not use the tool adapters.
(2) Ensure that the tool and the pulley remain
aligned with the pump shaft. Prevent the pulley from
being cocked o

(1) Install the pulley with Installer C-4063 (Fig.
15). Do not use the tool adapters.
(2) Ensure that the tool and the pulley remain
aligned with the pump shaft. Prevent the pulley from
being cocked on the shaft.
(3) Install the pulley until it is flush with the end
of the power steering pump shaft (Fig. 16).
(4) Install the power steering pump on the vehicle.INSTALLATION
INSTALLATION - PUMP (2.4L ENGINE)
(1) Install power steering pump back in vehicle
using the reverse order of its removal through the
exhaust tunnel 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.
CAUTION: Heat sleeve must cover entire rubber
portion of return hose to ensure desired thermal
protection from exhaust.
(10) Properly position the protective heat sleeve
over the power steering return hose. Securely 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.
Fig. 15 Pulley Installation
1 - POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL
C-4063±A
Fig. 16 Pulley To Pump Shaft Location
1 - PULLEY
2 - PUMP BODY
3 - PUMP SHAFT
4 - HUB
19 - 42 PUMPRS
PUMP (Continued)

Page 1588 of 2585

CHRYSLER VOYAGER 2004 Service Manual 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 steer

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 power steering pump mount-
ing bolts (Fig. 11). Tighten the 3 front 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.
(4) Install the power steering fluid pressure line
into the pressure output fitting of the power steering
pump (Fig. 10).Do not fully tighten tube nut at
this time.
(5) Install the power steering fluid supply hose on
the power steering pump supply fitting (Fig. 10).Be
sure hose clamp is properly installed.
(6) Raise the vehicle.
(7) Install the routing clip on the engine for the
pressure hose (Fig. 9) and tighten fastener.
(8) Install the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(9) Install the drive belt splash shield.
(10) Lower the vehicle.
(11) Tighten the pressure line to pump pressure
fitting tube nut to a torque of 31 N´m (275 in. lbs.).
(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.
INSTALLATION - PUMP (2.5L DIESEL)
(1) Install the power steering pump on its cast
mounting bracket.
(2) Install the three front power steering pump
mounting bolts. Tighten the mounting bolts to a
torque of 54 N´m (40 ft. lbs.).
(3) Install the rear mounting bolt fastening the
stamped bracket to the cast bracket (Fig. 13).
Tighten the mounting bolt 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.
(4) Install the power steering fluid pressure hose
fitting into the pressure port of the power steering
pump (Fig. 12). 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 supply hose on
the power steering pump supply fitting (Fig. 12).Be
sure hose clamp is properly reinstalled.
(6) Install the accessary drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(7) Install the splash shields below the engine
compartment.
(8) Lower the vehicle.
(9) Connect the negative (-) battery cable on the
negative battery post.
(10) Fill and bleed the power steering system
using the Power Steering Pump Initial Operation
Procedure (Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
(11) Inspect for leaks.
SPECIAL TOOLS
POWER STEERING PUMP
Installer C-4063B
Puller C-4333
RSPUMP19-43
PUMP (Continued)

Page 1589 of 2585

CHRYSLER VOYAGER 2004 Service Manual FLUID
STANDARD PROCEDURE - POWER STEERING
FLUID LEVEL CHECKING
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT INJURY
FROM MOVING PARTS AND TO ENSURE ACCU-
RATE FLUID LEVEL READI

FLUID
STANDARD PROCEDURE - POWER STEERING
FLUID LEVEL CHECKING
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT INJURY
FROM MOVING PARTS AND TO ENSURE ACCU-
RATE FLUID LEVEL READING.
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. 17).
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 only
MopartATF+4 Automatic Transmission Fluid
(MS-9602) in the power steering system.For
additional information on Automatic Transmission
Fluid, (Refer to LUBRICATION & MAINTENANCE/
FLUID TYPES - DESCRIPTION).
CAUTION: Use only MoparTATF+4 Automatic Trans-
mission Fluid (MS-9602). Use of other MoparT
power steering fluids (MS5931 and MS9933) should
be avoided to ensure peak performance of the
power steering system under all operating condi-
tions.
FLUID COOLER
DESCRIPTION
All models (except 2.5L Diesel) 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. 18).
There are two different size coolers depending on
model and options. There is a standard 6-inch and an
8-inch.
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.
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 the cooler
which it has absorbed from the power steering fluid
flowing through it. The cooler is placed in the power
steering fluid return line, between the steering gear
and the power steering fluid reservoir.
REMOVAL
(1) Using a siphon pump, remove as much fluid as
possible from the power steering fluid reservoir.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(3) Remove the hose clamps at the cooler and
remove the hoses from the cooler inlet and outlet
tubes.
(4) Remove the 2 bolts attaching the power steer-
ing cooler cradle crossmember reinforcement (Fig.
18). Remove the cooler.
Fig. 17 Power Steering Fluid Reservoir
Fig. 18 Power Steering Cooler
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
19 - 44 PUMPRS

Page 1590 of 2585

CHRYSLER VOYAGER 2004 Service Manual INSTALLATION
(1) Install the power steering fluid cooler on the
cradle crossmember reinforcement (Fig. 18). Install
the mounting bolts and tighten to 11 N´m (100 in.
lbs.).
(2) Install power steering

INSTALLATION
(1) Install the power steering fluid cooler on the
cradle crossmember reinforcement (Fig. 18). Install
the mounting bolts and tighten to 11 N´m (100 in.
lbs.).
(2) Install power steering fluid hoses on the cooler.
Be sure hose clamps are installed on hose past
the upset bead on the power steering cooler
tubes.
(3) Lower the vehicle to a point where front tires
are just off the ground.
(4) Perform Power Steering Pump Initial Opera-
tion procedure. (Refer to 19 - STEERING/PUMP -
STANDARD PROCEDURE)
HOSE - POWER STEERING
PRESSURE
REMOVAL
REMOVAL - 2.4L ENGINE
NOTE: Before proceeding, review all WARNINGS
and CAUTIONS. (Refer to 19 - STEERING/PUMP -
WARNING)(Refer to 19 - STEERING/PUMP - CAU-
TION)
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(5) Place an oil drain pan under vehicle to catch
power steering fluid.
(6) Back out pressure hose tube nut at power
steering pump pressure fitting and remove hose from
pump (Fig. 19).
(7) Remove bolt attaching right routing clamp to
front suspension cradle crossmember (Fig. 19).
Remove pressure hose from clamp.
(8) Back out pressure hose tube nut at power
steering gear and remove hose from gear (Fig. 19).
(9) Remove power steering fluid pressure hose
from vehicle.
REMOVAL - 3.3L/3.8L ENGINE
NOTE: Before proceeding, review all WARNINGS
and CAUTIONS. (Refer to 19 - STEERING/PUMP -
WARNING)(Refer to 19 - STEERING/PUMP - CAU-
TION)
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(5) Remove two bolts securing pressure hose rout-
ing clamps to suspension cradle crossmember and
steel reinforcement (Fig. 20).
(6) Place an oil drain pan under vehicle to catch
draining power steering fluid.
(7) Disconnect pressure hose at power steering
gear (Fig. 20).
Fig. 19 PRESSURE AND RETURN HOSES - 2.4L
1 - POWER STEERING PUMP
2 - RETURN HOSE (HEAT SLEEVE COVERED)
3 - ROUTING CLAMPS
4 - PRESSURE HOSE TUBE NUT
5 - RETURN HOSE TUBE NUT
6 - CRADLE CROSSMEMBER
7 - POWER STEERING GEAR
8 - PRESSURE HOSE
RSPUMP19-45
FLUID COOLER (Continued)

Page 1591 of 2585

CHRYSLER VOYAGER 2004 Service Manual (8) Remove pressure hose routing bracket bolt at
engine (Fig. 21). Bolt can be accessed through hole in
cradle crossmember (Fig. 22).
(9) Disconnect pressure hose tube nut at power
steering pump (Fig.

Page 1592 of 2585

CHRYSLER VOYAGER 2004 Service Manual CAUTION: When tightening and torquing the pres-
sure hose at the power steering pump, the pressurehose is to be rotated against the fluid return hose
fitting on the pump.
(8) Tighten pressure hose tub

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