Chrysler RG Voyager. Manual - part 993

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.
19). Remove the cooler.

INSTALLATION

(1) Install the power steering fluid cooler on the

cradle crossmember reinforcement (Fig. 19). 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 - WARN-
ING) (Refer to 19 - STEERING/PUMP - CAUTION)

(1) Remove cap from power steering fluid reservoir.
(2) Using a siphon pump, remove as much power

steering fluid as possible from power steering fluid res-
ervoir.

(3) Raise vehicle. (Refer to LUBRICATION &

MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)

(4) Remove front emissions vapor canister. (Refer

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. 20).

Fig. 19 Power Steering Cooler

1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER

Fig. 20 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

PUMP

19 - 47

FLUID COOLER (Continued)

(7) Remove bolt attaching right routing clamp to

front

suspension

cradle

crossmember

(Fig.

20).

Remove pressure hose from clamp.

(8) Back out pressure hose tube nut at power

steering gear and remove hose from gear (Fig. 20).

(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

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. 21).

(6) Place an oil drain pan under vehicle to catch

draining power steering fluid.

(7) Disconnect pressure hose at power steering

gear (Fig. 21).

Fig. 21 HOSES TO POWER STEERING GEAR - 3.3L/3.8L ENGINE

1 - RETURN HOSE (TO RESERVOIR)
2 - PRESSURE HOSE (FROM PUMP)
3 - CRADLE CROSSMEMBER
4 - PRESSURE HOSE ROUTING CLAMP
5 - RETURN HOSE ROUTING CLAMP
6 - PRESSURE HOSE TUBE NUT

7 - POWER STEERING GEAR
8 - ABS BRACKET
9 - ROUTING CLIP
10 - LEAK DETECTION PUMP FILTER
11 - RETURN HOSE TUBE NUT
12 - ROUTING CLIP

19 - 48

PUMP

HOSE - POWER STEERING PRESSURE (Continued)

(8) Remove pressure hose routing bracket bolt at

engine (Fig. 22). Bolt can be accessed through hole in
cradle crossmember (Fig. 23).

(9) Disconnect pressure hose tube nut at power

steering pump (Fig. 22).

(10) Remove power steering fluid pressure hose

from vehicle.

INSTALLATION

INSTALLATION - 2.4L ENGINE

(1) Remove any used O-rings from ends of power

steering hose.

(2) Using a lint free towel, wipe clean hose ends,

power steering pump pressure outlet fitting and
steering gear port.

(3) Install new O-rings on ends of power steering

fluid pressure hose. Lubricate O-rings using clean
power steering fluid.

CAUTION: Use care not to bend tube ends of power
steering hoses when installing. Leaks and restric-
tions may occur.

CAUTION: Power steering fluid hoses must remain
away from exhaust system and must not come in
contact with any unfriendly surfaces on vehicle.

Fig. 22 RESERVOIR AND HOSES - 3.3L/3.8L

1 - RESERVOIR
2 - ROUTING CLIP (2001 ONLY)
3 - SUPPLY HOSE
4 - POWER STEERING PUMP

5 - PRESSURE HOSE (TO GEAR)
6 - ROUTING BRACKET
7 - RETURN HOSE (FROM GEAR)

Fig. 23 PRESSURE HOSE ROUTING CLAMP

1 - PRESSURE HOSE TUBE
2 - STEERING GEAR
3 - CRADLE CROSSMEMBER
4 - DRIVESHAFT
5 - ROUTING CLAMP BRACKET

PUMP

19 - 49

HOSE - POWER STEERING PRESSURE (Continued)

(4) Route hose up through cradle crossmember

toward power steering pump avoiding tight bends or
kinking.

(5) Install power steering pressure hose end into

pump pressure outlet fitting (Fig. 20). Thread tube
nut into outlet fitting, but do not tighten at this time.

(6) Route hose behind cradle crossmember and

start hose end into gear port. Do not tighten hose
tube nut at this time.

(7) Install hose into right routing clamp (Fig. 20),

then install mounting bolt into cradle crossmember.
Tighten bolt to 23 N·m (200 in. lbs.) torque.

CAUTION: When tightening and torquing the pres-
sure hose at the power steering pump, the pressure
hose is to be rotated against the fluid return hose
fitting on the pump.

(8) Tighten pressure hose tube nuts at pump and

gear to 31 N·m (275 in. lbs.) torque.

(9) Install front emissions vapor canister. (Refer to

25 - EMISSIONS CONTROL/EVAPORATIVE EMIS-
SIONS/VAPOR CANISTER - INSTALLATION)

(10) Lower vehicle.
(11) Fill and bleed the power steering system

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

(12) Inspect system for leaks.

INSTALLATION - 3.3L/3.8L ENGINE

(1) Remove any used O-rings from ends of power

steering hose.

(2) Using a lint free towel, wipe clean hose ends,

power steering pump pressure outlet fitting and
steering gear port.

(3) Install new O-rings on ends of power steering

fluid pressure hose. Lubricate O-rings using clean
power steering fluid.

CAUTION: Use care not to bend tube ends of the
power steering hoses when installing. Leaks and
restrictions may occur.

CAUTION: Power steering fluid hoses must remain
away from the exhaust system and must not come
in contact with any unfriendly surfaces on the vehi-
cle.

(4) Route hose up behind engine toward pump

avoiding tight bends or kinking.

(5) Install power steering pressure hose end into

pump pressure outlet fitting (Fig. 22). Thread tube
nut into outlet fitting, but do not tighten at this time.

(6) Attach pressure hose routing bracket to engine

(Fig. 22). Tighten bolt to 23 N·m (200 in. lbs.) torque.

(7) Tighten hose tube nut at pump outlet fitting to

31 N·m (275 in. lbs.) torque.

(8) Route hose behind cradle crossmember and

start hose end into gear port. Do not tighten hose
tube nut at this time.

(9) Attach hose to suspension cradle crossmember

and steel reinforcement using two routing clamps
and bolts (Fig. 21). Tighten clamp bolt at steel rein-
forcement to 11 N·m (100 in. lbs.) torque. Tighten
clamp bolt at cradle crossmember to 23 N·m (200 in.
lbs.) torque.

(10) Tighten hose tube nut at power steering gear

port to 31 N·m (275 in. lbs.) torque.

(11) Install front emissions vapor canister. (Refer

EMISSIONS

CONTROL/EVAPORATIVE

EMISSIONS/VAPOR CANISTER - INSTALLATION)

(12) Lower vehicle.
(13) Fill and bleed the power steering system

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

(14) Inspect system for leaks.

HOSE - POWER STEERING
RETURN

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

EMISSIONS

CONTROL/EVAPORATIVE

EMISSIONS/VAPOR CANISTER - REMOVAL)

(5) Place an oil drain pan under vehicle to catch

power steering fluid.

(6) Cut tie-strap securing insulating heat sleeve to

power steering fluid return hose near power steering
pump. Pull back heat sleeve to expose hose clamp.

(7) Remove clamp, then return hose from power

steering pump (Fig. 20).

(8) Remove 2 bolts attaching power steering cooler

to cradle crossmember reinforcement (Fig. 24).

19 - 50

PUMP

HOSE - POWER STEERING PRESSURE (Continued)

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