Content .. 988 989 990 991 ..

Chrysler RG Voyager. Manual - part 990

(13) Reconnect previously disconnected hose at

power steering cooler and install clamp.

(14) Install the front tire and wheel assemblies on

vehicle. Install the wheel lug nuts and torque to 135
N·m (100 ft. lbs.).

(15) Install front emissions vapor canister. (Refer

EMISSIONS

CONTROL/EVAPORATIVE

EMISSIONS/VAPOR CANISTER - INSTALLATION)

(16) Lower the vehicle to a level where the interior

of vehicle is accessible.

(17) With

the

wheels

pointed

approximately

STRAIGHT-AHEAD, align the intermediate shaft
with the steering column coupler. Assemble the steer-
ing column shaft coupler onto the steering gear inter-
mediate coupler (Fig. 2). Install steering column
coupler to intermediate shaft retaining pinch bolt.
Tighten the pinch bolt nut to a torque of 28 N·m (250
in. lbs.).

(18) Remove the steering wheel holding tool.
(19) Fill and bleed the power steering system

using the Power Steering Pump Initial Operation
Procedure. (Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE)

(20) Inspect system for leaks.
(21) Adjust front toe (Refer to 2 - SUSPENSION/

WHEEL ALIGNMENT - STANDARD PROCEDURE).

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. 12). 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 2 steering gear mounting
bolts and nuts. Tighten the M-14 size steering gear
to suspension cradle mounting bolt to a torque of 183
N·m (135 ft. lbs.). Tighten the M-12 size steering
gear to suspension cradle mounting bolt to a torque
of 95 N·m (70 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. 10).

(6) Attach the power steering fluid pressure and

return hoses to the proper fittings on the steering

gear (Fig. 10). 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. 11).

(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. 4), tighten tie rod end
to steering knuckle attaching nut. Then using a
crowfoot and socket (Fig. 13), 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. 6). 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. 6). Tighten bolts to a torque of
163 N·m (120 ft. lbs.).

(14) If power steering cooler equipped, install the

previously disconnected power steering cooler hose on
the cooler. Install the clamp.

(15) If power steering cooler equipped, install the

power steering fluid cooler on the cradle crossmem-
ber reinforcement (Fig. 3). Install the mounting bolts
and tighten to 11 N·m (100 in. lbs.).

(16) Install the front tire and wheel assemblies on

vehicle. Install the wheel mounting lug nuts and
tighten to a torque to 135 N·m (100 ft. lbs.).

(17) Lower the vehicle to a level were the interior

of vehicle is accessible (keeping tires off the ground).

(18) With

the

wheels

pointed

approximately

GEAR

19 - 35

GEAR (Continued)

Tighten the pinch bolt nut to a torque of 28 N·m (250
in. lbs.).

(19) Remove the steering wheel holding tool.
(20) 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)

(21) Inspect for leaks.
(22) Adjust front wheel toe (Refer to 2 - SUSPEN-

SION/WHEEL ALIGNMENT - STANDARD PROCE-
DURE).

SPECIAL TOOLS

POWER STEERING GEAR

OUTER TIE ROD

REMOVAL

(1) Loosen inner tie rod to outer tie rod jam nut

(Fig. 14).

(2) Remove nut attaching outer tie rod end to

steering knuckle (Fig. 15). The nut is to be removed
from tie rod end by holding tie rod end stud with a
11/32 socket while loosening and removing nut with a
wrench.

Puller C-3894A

Remover/Installer Steering Shaft Roll Pin 6831A

Fig. 14 Inner To Outer Tie Rod Jam Nut

1 - INNER TIE ROD SERRATION
2 - OUTER TIE ROD JAM NUT
3 - OUTER TIE ROD END
4 - INNER TIE ROD
5 - STEERING KNUCKLE

Fig. 15 Tie Rod End Attaching Nut (Typical)

1 - TIE ROD END
2 - STEERING KNUCKLE
3 - WRENCH
4 - SOCKET
5 - TIE ROD END STUD

19 - 36

GEAR

GEAR (Continued)

(3) Remove the tie rod end stud from steering

knuckle arm, using Remover, Special Tool C-3894–A
(Fig. 16).

(4) Remove outer tie rod end by un-threading it

from the inner tie rod.

INSTALLATION

NOTE: Before installing the outer tie rod, make sure
the jam nut is on inner tie rod (Fig. 14).

(1) Install outer tie rod onto inner tie rod.

(2) Do not tighten jam nut.
(3) Install tie rod end into the 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, tighten tie rod end to steering
knuckle attaching nut (Fig. 15). Then using a crow-
foot and 11/32 socket (Fig. 17), torque tie rod end
attaching nut to 75 N·m (55 ft. lbs.).

(4) Tighten tie rod jam nut (Fig. 14) to 75 N·m (55

ft. lbs.) torque.

CAUTION: During this procedure do not allow the
steering gear boot to become twisted.

(5) Adjust the front toe setting on the vehicle

(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).

Fig. 16 TIE ROD REMOVAL WITH TOOL C-3894-A

1 - OUTER TIE ROD
2 - SPECIAL TOOL C-3894-A
3 - STEERING KNUCKLE

Fig. 17 Torquing Tie Rod End Attaching Nut

1 - STEERING KNUCKLE
2 - TIE ROD END
3 - CROWFOOT
4 - SOCKET
5 - TORQUE WRENCH

GEAR

19 - 37

OUTER TIE ROD (Continued)

PUMP

TABLE OF CONTENTS

page

PUMP

DESCRIPTION

DESCRIPTION - PUMP (2.4L/3.3L/3.8L

ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

DESCRIPTION - PUMP (DIESEL)

. . . . . . . . . 38

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 39

WARNING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

CAUTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

STANDARD PROCEDURE - POWER

STEERING PUMP INITIAL OPERATION

. . . . . 39

REMOVAL

REMOVAL - PUMP (2.4L ENGINE)

. . . . . . . . . 40

REMOVAL - PUMP (3.3L/3.8L ENGINE)

. . . . . 42

REMOVAL - PUMP (DIESEL)

. . . . . . . . . . . . . 43

DISASSEMBLY - PUMP (PULLEY)

. . . . . . . . . . 43

ASSEMBLY - PUMP (PULLEY)

. . . . . . . . . . . . . 44

INSTALLATION

INSTALLATION - PUMP (2.4L ENGINE)

. . . . . 44

INSTALLATION - PUMP (3.3L/3.8L ENGINE)

. 45

INSTALLATION - PUMP (DIESEL)

. . . . . . . . . 45

SPECIAL TOOLS

POWER STEERING PUMP

. . . . . . . . . . . . . . 46

FLUID

STANDARD PROCEDURE - POWER

STEERING FLUID LEVEL CHECKING

. . . . . . 46

FLUID COOLER

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 46

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 46

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 47

HOSE - POWER STEERING PRESSURE

REMOVAL

REMOVAL - 2.4L ENGINE

. . . . . . . . . . . . . . . 47

REMOVAL - 3.3L/3.8L ENGINE

. . . . . . . . . . . 48

INSTALLATION

INSTALLATION - 2.4L ENGINE

. . . . . . . . . . . 49

INSTALLATION - 3.3L/3.8L ENGINE

. . . . . . . . 50

HOSE - POWER STEERING RETURN

REMOVAL

REMOVAL - 2.4L ENGINE

. . . . . . . . . . . . . . . 50

REMOVAL - 3.3L/3.8L ENGINE

. . . . . . . . . . . 51

INSTALLATION

INSTALLATION - 2.4L ENGINE

. . . . . . . . . . . 51

INSTALLATION - 3.3L/3.8L ENGINE

. . . . . . . . 52

HOSE - POWER STEERING SUPPLY

REMOVAL

REMOVAL - 2.4L ENGINE

. . . . . . . . . . . . . . . 52

REMOVAL - 3.3L/3.8L ENGINE

. . . . . . . . . . . 52

INSTALLATION

INSTALLATION - 2.4L ENGINE

. . . . . . . . . . . 53

INSTALLATION - 3.3L/3.8L ENGINE

. . . . . . . . 53

RESERVOIR - POWER STEERING FLUID

DESCRIPTION

DESCRIPTION - 2.4L/3.3L/3.8L ENGINE

. . . . 53

DESCRIPTION - DIESEL

. . . . . . . . . . . . . . . . 53

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 53

REMOVAL

REMOVAL - 2.4L ENGINE

. . . . . . . . . . . . . . . 53

REMOVAL - 3.3L/3.8L ENGINE

. . . . . . . . . . . 53

REMOVAL - DIESEL

. . . . . . . . . . . . . . . . . . . 54

INSTALLATION

INSTALLATION - 2.4L ENGINE

. . . . . . . . . . . 54

INSTALLATION - 3.3L/3.8L ENGINE

. . . . . . . . 54

INSTALLATION - DIESEL

. . . . . . . . . . . . . . . . 54

PUMP

DESCRIPTION

DESCRIPTION - PUMP (2.4L/3.3L/3.8L
ENGINE)

Hydraulic pressure for the operation of the power

steering gear is provided by a belt driven power
steering pump. The power steering pump is mounted
on the back side of the engine on all engine applica-
tions. The pumps are different depending on the
engine option. The pump for the 2.4L engine is made

out of cast iron and steel (Fig. 1). The pump used on
the 3.3L/3.8L engine is made of aluminum (Fig. 2).

The pump for the 3.3L/3.8L engine does not have a

return fitting as the pump for the 2.4L engine does.
The power steering return hose on the 3.3L/3.8L
engine goes to the reservoir instead of the pump.

DESCRIPTION - PUMP (DIESEL)

Hydraulic pressure for the operation of the power

steering gear is provided by a belt driven power
steering pump. The power steering pump is mounted
front lower right corner of the engine (Fig. 13).

The pump has a supply fitting for fluid coming

from the reservoir and a pressure port for exiting
fluid that is headed for the steering gear.

19 - 38

PUMP

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