torque CHRYSLER CARAVAN 2005 Service Manual

(2) Feed and route wiring from clockspring
through upper access hole in steering wheel.
(3) Align master serrations in steering wheel with
omitted spline on steering column shaft (at 12 o'clock
position). Slide the steering wheel onto the steering
column shaft by hand (Fig. 42). Use care not to pinch
any wiring.
NOTE: Before installing the damper on the steering
wheel, inspect the damper to ensure the rubber iso-
lator on the damper is not deteriorated or damaged.
If the damper is installed with a damaged isolator, a
buzz, squeak or rattle condition may develop.
(4) Install the damper on the steering wheel (Fig.
42).
(5) Install the steering wheel retaining bolt.
Tighten the steering wheel retaining bolt to 61 N´m
(45 ft. lbs.) torque.(6) If the steering wheel is equipped with remote
audio controls, connect the wiring connector to the
clockspring (Fig. 42).
(7) Connect the airbag squib wiring connectors to
the airbag and the horn and speed control switch
connector to the clockspring (Fig. 41).
(8) Install the driver airbag in the steering wheel
(Fig. 40). Install and tighten the airbag attaching
screws to 10 N´m (90 in. lbs.) torque.
(9) Connect the battery negative (ground) cable to
battery post following special Diagnosis And Testing
procedure. (Refer to 8 - ELECTRICAL/RESTRAINTS
- DIAGNOSIS AND TESTING)
(10) Check operation of all steering wheel mounted
components.
(11) Road test vehicle to ensure proper operation of
steering.
RSCOLUMN19-25
STEERING WHEEL (Continued)

(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.
CAUTION: Proper torque on the steering gear to
suspension cradle mounting bolts is very impor-
tant.
(4) Install steering gear on the front suspension
cradle. Install the 3 steering gear mounting bolts and
nuts (Fig. 8). Tighten the 3 mounting bolts to the fol-
lowing torque values:
²14 mm bolt ± 183 N´m (135 ft. lbs.) torque
²12 mm bolt ± 95 N´m (70 ft. lbs.) torque
(5) Attach the power steering fluid pressure and
return hoses to the correct ports on the power steer-
ing gear (Fig. 7). Tighten the hose tube nuts at the
gear to a torque of 31 N´m (275 in. lbs.).
(6) If the vehicle is equipped with All-Wheel-Drive,
install the power transfer unit as necessary (Refer to
21 - TRANSMISSION/TRANSAXLE/POWER
TRANSFER UNIT).
CAUTION: Proper torque on the cradle reinforce-
ment to suspension cradle mounting bolts is very
important.
(7) 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
153 N´m (113 ft. lbs.). Tighten the M-12 size bolts to
a torque of 106 N´m (78 ft. lbs.).(8) Install the lower control arm rear bushing
retainer bolts (M-10 size) through reinforcement on
each side of each lower control arm rear bushing.
Tighten bolts to a torque of 61 N´m (45 ft. lbs.).
(9) 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.).
(10) Install outer tie rod end into steering knuckle.
Start outer tie rod 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.).
(11) Install leak detection pump on cradle cross-
member reinforcement. (Refer to 25 - EMISSIONS
CONTROL/EVAPORATIVE EMISSIONS/LEAK
DETECTION PUMP - INSTALLATION)
(12) Install the power steering fluid cooler on the
cradle crossmember reinforcement (Fig. 3). Install
the mounting bolts and tighten to 11 N´m (100 in.
lbs.). When installing mounting bolts, include pres-
sure hose routing clamp.
(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
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - INSTALLATION)
(16) Lower the vehicle to a level where the interior
of vehicle is accessible.
Fig. 12 Installing Roll Pin In Intermediate Coupler
1 - INTERMEDIATE SHAFT COUPLER
2 - SUSPENSION CRADLE CROSSMEMBER
3 - KNURLED NUT
4 - ROLL PIN
5 - POWER STEERING GEAR
Fig. 13 Torquing Tie Rod End Attaching Nut
1 - STEERING KNUCKLE
2 - TIE ROD END
3 - CROWFOOT
4 - SOCKET
5 - TORQUE WRENCH
19 - 32 GEARRS
GEAR (Continued)

(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 ontostud 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
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.).
(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).
RSGEAR19-33
GEAR (Continued)

(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. 17 Torquing Tie Rod End Attaching Nut
1 - STEERING KNUCKLE
2 - TIE ROD END
3 - CROWFOOT
4 - SOCKET
5 - TORQUE WRENCH
RSGEAR19-35
OUTER TIE ROD (Continued)

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.
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 (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.).
RSPUMP19-43
PUMP (Continued)

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
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.
Installer C-4063B
Puller C-4333
Fig. 17 Power Steering Fluid Reservoir
19 - 44 PUMPRS
PUMP (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.
(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.
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 NUT7 - POWER STEERING GEAR
8 - ABS BRACKET
9 - ROUTING CLIP
10 - LEAK DETECTION PUMP FILTER
11 - RETURN HOSE TUBE NUT
12 - ROUTING CLIP
RSPUMP19-47
HOSE - POWER STEERING PRESSURE (Continued)

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.
Fig. 22 RESERVOIR AND HOSES - 3.3L/3.8L
1 - RESERVOIR
2 - ROUTING CLIP (2001 ONLY)
3 - SUPPLY HOSE
4 - POWER STEERING PUMP5 - 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
19 - 48 PUMPRS
HOSE - POWER STEERING PRESSURE (Continued)

(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
to 25 - 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
to 25 - 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).
(9) Remove bolts attaching routing clamps to front
suspension cradle crossmember (Fig. 20). Remove
return hose from clamps.
(10) Back out return hose tube nut at power steer-
ing gear and remove hose (Fig. 20).
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) Place an oil drain pan under vehicle to catch
any draining power steering fluid.
(4) Remove clamp attaching return hose to power
steering fluid reservoir. Disconnect hose from reser-
voir (Fig. 22).
(5) Follow return hose downward and open
retainer at ABS bracket (Fig. 21). Remove hose tube
from retainer.
(6) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(7) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(8) Remove bolt securing return hose routing
clamp to suspension cradle crossmember (Fig. 21).
RSPUMP19-49
HOSE - POWER STEERING PRESSURE (Continued)

(9) Remove 2 bolts attaching power steering cooler
to cradle crossmember reinforcement (Fig. 24).
(10) Disconnect return hose at power steering gear
(Fig. 21).
(11) Remove power steering fluid return hose with
cooler 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 fitting and steering gear port.
(3) Install new O-ring on power steering gear end
of return hose. Lubricate O-ring 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: If a new return hose is being installed
and it does not have an insulating heat sleeve
installed, the heat shield from the original hose
must be transferred before hose installation.
(4) Route hose along rear of cradle crossmember
and start gear end of hose into gear port. Do not
tighten hose tube nut at this time.(5) Attach hose to suspension cradle crossmember
using two routing clamps and bolts (Fig. 20). Tighten
clamp bolts to 23 N´m (200 in. lbs.) torque.
(6) Tighten return hose tube nut at power steering
gear port to 31 N´m (275 in. lbs.) torque.
(7) Install the power steering fluid cooler on the
cradle crossmember reinforcement (Fig. 24). Install
the mounting bolts and tighten to 11 N´m (100 in.
lbs.).
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.
(8) Route pump end of hose over cradle crossmem-
ber toward pump avoiding tight bends or kinking.
(9) Install return hose onto power steering pump
return fitting and secure with hose clamp (Fig. 20).
Tighten the screw-type clamp to a torque of 2 N´m
(18 in. lbs.).
CAUTION: To prevent overheating of power steering
fluid return hose, protective heat shield sleeve must
cover entire rubber hose.
(10) Slide insulating heat shield up over the clamp
on the return hose and tie-strap it in place.
(11) Install front emissions vapor canister. (Refer
to 25 - 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.
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
and power steering gear hose port.
(3) Install a new O-ring on gear port end of power
steering fluid hose. Lubricate O-ring 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.
Fig. 24 POWER STEERING COOLER
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
19 - 50 PUMPRS
HOSE - POWER STEERING RETURN (Continued)