tow CHRYSLER VOYAGER 1996 Service Manual

REMOVAL AND INSTALLATION
ACCELERATOR PEDAL
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing the accelerator pedal or throttle cable.
REMOVAL
(1) Disconnect electrical connector.
(2) Remove accelerator pedal mounting bracket
nuts. Remove accelerator pedal assembly.
INSTALLATION
(1) Place accelerator pedal assembly over studs
protruding from floor pan. Tighten mounting nuts to
5 N´m (46 in. lbs.) torque.
(2) Connect electrical connector.
(3) Before starting the engine, operate the acceler-
ator pedal to check for any binding.
AIR CLEANER ELEMENT
REMOVAL
(1) Remove hose clamp at Mass Air Flow Sensor.
(2) Remove hose from Mass Air Flow Sensor.(3) Loosen 2 clamps holding air cleaner housing
halves together.
(4) Remove left side of air cleaner housing.
(5) Remove element from air cleaner housing.
INSTALLATION
(1) Install a new element in housing.
(2) Position left side of housing.
(3) Snap clamps into place.
(4) Install hoses and clamps.
FUEL DRAIN TUBES
The fuel drain tubes (Fig. 28) are low±pressure
type.
Pull each tube from the injector for removal. Push
on for installation. Clamps are not required for these
tubes.
FUEL FILTER/WATER SEPARATOR
The fuel filter/water separator is located in the
engine compartment on the right side near the shock
tower. (Fig. 29).
The fuel filter/water separator assembly contains
the fuel filter, fuel heater element, and fuel drain
valve (Fig. 29).
DRAINING WATER FROM FILTER BOWL
Moisture (water) collects at the bottom of the filter/
separator in a plastic bowl. Water entering the fuel
injection pump can cause serious damage to the
pump.Note that the bulb will be illuminated for
approximately 2 seconds each time the key is
initially placed in the ON position. This is done
for a bulb check.
Fig. 27 Accelerator Pedal Mounting-Typical
Fig. 28 Fuel Drain Tubes
14 - 16 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS

WARNING: DO NOT ATTEMPT TO DRAIN WATER
FROM THE FILTER/SEPARATOR WITH THE ENGINE
HOT.
(1) The bottom of the filter/separator bowl is
equipped with a drain valve (Fig. 29). The drain
valve is equipped with a fitting. Attach a piece of
rubber hose to this fitting. This hose is to be used as
a drain hose.
(2) Place a drain pan under the drain hose.
(3) With the engine not running, open the drain
valve (unscrewÐdrain valve has right hand threads)
from the filter/separator bowl. To gain access to this
fitting, the two filter±to±mounting bracket nuts (Fig.
29) may have to be loosened a few turns.
(4) Hold the drain open until clean fuel exits the
drain.
(5) After draining, close drain valve.
(6) Remove rubber drain hose.
(7) Dispose of mixture in drain pan according to
applicable local or federal regulations.
FUEL FILTER REMOVAL
(1) Drain all fuel and/or water from fuel filter/wa-
ter separator assembly. Refer to the previous Drain-
ing Water From Filter Bowl.
(2) Unplug the electrical connectors at bottom of
plastic bowl.
(3) Remove plastic bowl from bottom of fuel filter
(unscrews).
(4) Remove fuel filter from bottom of filter base
(unscrews).
FUEL FILTER INSTALLATION
(1) Clean bottom of fuel filter base.
(2) Apply clean diesel fuel to new fuel filter gasket.
(3) Install and tighten filter to filter base. The bev-
eled part of the rubber gasket should be facing up
towards the filter base.
(4) Clean the inside of bowl with a soap and water
mixture before installation. Carefully clean any resi-
due between the two metal probes at the top of the
water±in±fuel sensor. Do not use chemical cleaners
as damage to the plastic bowl may result.
(5) Pour diesel fuel into the plastic bowl before
installing bowl to bottom of fuel filter. Do this to help
prevent air from entering fuel injection pump while
attempting to starting engine.
(6) Install filter bowl to bottom of filter.
(7) Install the electrical connectors at bottom of
bowl.
(8) Tighten the filter±to±mounting bracket nuts
(Fig. 29) to 28 N´m (250 in. lbs.) torque.
FUEL HEATER
If the fuel heater element needs replacement, the
plastic filter bowl assembly must be replaced. Refer
to Fuel Filter/Water Separator for information.
FUEL HEATER RELAY
The fuel heater relay is located in the PDC. For
the location of the relay within the PDC (Fig. 30),
refer to label on PDC cover.
Fig. 29 Fuel Filter/Water Separator Location
Fig. 30 Power Distribution Center (PDC) Location
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 17
REMOVAL AND INSTALLATION (Continued)

one injector, thread the wiring harness through the
access hole on the special socket (Fig. 49).
(6) Remove and discard the copper washer (seal) at
bottom of injector (Fig. 47).
INSTALLATION
(1) Clean the injector threads in cylinder head.
(2) Install new copper washer (seal) to injector.
(3) Install injector to engine. Tighten to 70 N´m
(52 ft. lbs.) torque.
(4) Install high±pressure fuel lines. Refer to High-
±Pressure Fuel Lines in this group for procedures.
(5) Install fuel drain hoses (tubes) to each injector.
Do not use clamps at fuel drain hoses.
(6) Connect negative battery cable to battery.
(7) Bleed the air from the high±pressure lines.
Refer to the Air Bleed Procedure section of this
group.
FUEL SHUTDOWN SOLENOID
The solenoid is mounted to the rear of the injection
pump (Fig. 50).
REMOVAL
(1) Thoroughly clean the area around the solenoid
with compressed air.
(2) Disconnect the fuel return line and banjo fit-
ting above the solenoid by removing (un±threading)
the overflow valve (Fig. 50). Place a towel below the
valve before removal. Discard old sealing washers
after removal.
(3) Disconnect the electrical connector nut (Fig.
50).
(4) Remove wiring at solenoid.
(5) Remove solenoid from injection pump.
INSTALLATION
(1) Install solenoid into injection pump.
(2) Install wiring and nut at solenoid.
(3) Install new sealing washers to banjo fitting.
(4) Install overflow valve, banjo fitting and fuel
return line to pump.
(5) Bleed air from system. Refer to Air Bleed Pro-
cedures in this section of the group.
FUEL TANK
REMOVAL
(1) Disconnect negative cable from battery.
(2) Insert fuel siphon hose into fuel filler neck and
push it into the tank.
(3) Drain fuel tank dry into holding tank or a
properly labeleddieselsafety container.
Fig. 48 Fuel InjectorÐTypical
Fig. 49 Wiring Harness Through Socket
Fig. 50 Fuel Shutdown Solenoid Location
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 23
REMOVAL AND INSTALLATION (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 line
onto the output fitting of the power steering pump
(Fig. 21). 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, low pressure
return hose on the power steering pump low pressure
fitting (Fig. 21).Be sure hose clamps are prop-
erly reinstalled.
(6) Install the power steering fluid supply hose
from the power steering fluid reservoir, on the power
steering pump fluid fitting (Fig. 21).Be sure hose is
clear of accessory drive belts and all hose
clamps are properly reinstalled.
(7) Install the serpentine drive belt (Fig. 20). See
Cooling, Group 7 for detailed installation procedure.
(8) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig.
18).
(9) Install a screw type hose clamp on the power
steering hose to steel tube connection.Be sure hose
clamps are properly reinstalled.Tighten the screw
clamp to a torque of 2 N´m (18 in. lbs.).
CAUTION: The protective heat shield sleeves must
cover the entire rubber hose and hose to tube con-
nection portion of both the power steering fluid
pressure and return hoses (Fig. 18). This is required
to keep the power steering hoses from becoming
overheated.
(10) When used, properly position the protective
heat sleeves on the power steering hoses (Fig. 18).
Then, tie strap the heat sleeves to the power steering
hoses to keep them in their proper position.
(11) Install the exhaust pipe on the exhaust man-
ifold. Install all exhaust system hangers/isolators on
the exhaust system brackets.
(12) Connect the oxygen sensor wiring harness to
the vehicle wiring harness. Install wiring harness
grommet in the floor pan of the vehicle.
(13) Install the accessory drive splash shield (Fig.
19).
(14) Lower vehicle.
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use MoparT, Power
Steering Fluid, or equivalent.
(15) Fill the remote power steering pump fluid res-
ervoir to correct fluid level.
(16) Install cap on power steering fluid reservoir.(17) Connect the negative battery cable on the
negative battery post.
(18) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
POWER STEERING FLUID RESERVOIR TO PUMP
SUPPLY HOSE
REMOVE
(1) Remove the filler cap from remote power steer-
ing fluid reservoir (Fig. 24).
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) Remove power steering fluid supply hose rout-
ing clip (Fig. 25) from stud in strut tower.
(4) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
Fig. 24 Fluid Supply Hose At Power Steering Fluid
Reservoir
Fig. 25 Power Steering Fluid Hose Routing Clip
19 - 18 STEERINGNS
REMOVAL AND INSTALLATION (Continued)

cation and Maintenance section of this service man-
ual, for the required lifting procedure to be used for
this vehicle.
(5) Remove at power steering pump, the power
steering fluid hose coming from the power steering
fluid reservoir. Let the power steering fluid drain out
of the reservoir and hose.
(6) Lower vehicle.
(7) Remove hose clamp attaching the power steer-
ing fluid supply hose to the power steering fluid res-
ervoir (Fig. 24).
(8) Remove the power steering fluid supply hose
from the vehicle. Hose is removed from the top of the
engine compartment.
INSTALL
CAUTION: On V-6 engine applications, the power
steering fluid reservoir to power steering hose must
be routed tightly against the strut tower and parallel
to the dash panel. It must also be routed under the
wiring harness and below the drip tube. This rout-
ing will prevent the power steering fluid supply
hose from coming in contact with the accessory
drive belt.
(1) Install and correctly route the power steering
fluid supply hose from remote fluid reservoir down to
power steering pump.
(2) Install the fluid supply hose onto the power
steering fluid reservoir (Fig. 24). Install the hose
clamp on the fluid supply hose.Be sure hose clamp
is installed past bead on fluid reservoir fitting.
(3) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this service man-
ual, for the required lifting procedure to be used for
this vehicle.
(4) Install power steering fluid supply hose on
power steering pump. Install the hose clamp on the
fluid supply hose.Be sure hose clamp is installed
past bead on pump fitting.
(5) Lower vehicle.
(6) Install routing clip on power steering fluid sup-
ply hose. Be sure routing clip is installed in a posi-
tion to correctly align with stud in strut tower.
(7) Install routing clip for power steering fluid sup-
ply hose on stud in strut tower (Fig. 25).
(8) Fill the remote fluid reservoir to the proper
level and let the fluid settle for at least two (2) min-
utes.
(9) Start the engine and let run for a few seconds.
Then turn the engine off.
(10) Add fluid if necessary. Repeat the above pro-
cedure until the fluid level remains constant after
running the engine.
(11) Raise the front wheels off the ground.(12) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
stops.
(13) Add power steering fluid if necessary.
(14) Lower the vehicle and turn the steering wheel
slowly from lock to lock.
(15) Stop the engine. Check the fluid level and
refill as required.
(16) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
POWER STEERING FLUID PRESSURE HOSE
Service all power steering hoses with vehicle raised
on hoist. Cap all open ends of hoses, power steering
pump fittings and steering gear ports to prevent
entry of foreign material into the components.
WARNING: POWER STEERING OIL, ENGINE
PARTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
For part reference and part location for the vehicle
that is being serviced, refer to the following figure
numbers. These show the hose bracket locations,
hose routings and fitting locations by the engine
application of the vehicle. Use these figure numbers
when referring to the removal or installation proce-
dures for the power steering hoses listed below.
REMOVE
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) Raise vehicle See Hoisting, Group 0. Put oil
drain pan under vehicle to catch power steering fluid.
(4) Raise the heat sleeve on the power steering
fluid return hose (Fig. 26) to expose the return hose
to steel tube connection. Remove the hose clamp from
the power steering fluid return hose (Fig. 26).
Remove power steering fluid return hose from steel
tube and allow power steering fluid to drain from
pump.
NSSTEERING 19 - 19
REMOVAL AND INSTALLATION (Continued)

(5) Remove the power steering fluid pressure line
from the power steering pump pressure fitting (Fig.
27). Drain excess power steering fluid from hose.
(6) Remove bolt, attaching power steering hose
routing bracket to front suspension cradle (Fig. 28).
(7) Disconnect power steering hose at power steer-
ing gear assembly (Fig. 29). Drain the power steering
fluid from power steering pump and hose.
(8) Discard the O-rings on the ends of power steer-
ing fluid pressure hose.
INSTALL
(1) Using a lint free towel, wipe clean the open
power steering hose ends, power steering pump pres-
sure fitting and steering gear ports.
(2) Install new O-rings on the ends of the power
steering fluid pressure hose. Lubricate O-rings using
clean power steering fluid.
(3) Attach the power steering pressure hose to the
fittings on the power steering pump and steering
gear. Route hose avoiding tight bends or kinking. Donot bend tube ends of the power steering hoses when
installing.
(4) Install the power steering fluid hoses to sus-
pension cradle routing bracket (Fig. 28). Power steer-
ing fluid hoses must remain away from the exhaust
system andmust notcome in contact with any
unfriendly surfaces of the vehicle.
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.
(5) Tighten all fasteners shown for specific applica-
tions to their correct torques listed below:
²Pump End Tube Nut 34 N´m (25 ft. lbs.)
²Gear End Tube Nut 34 N´m (25 ft. lbs.)
²Pump Bracket Nut 40 N´m (30 ft. lbs.)
Fig. 26 Return Hose Connection To Steel Tube
Fig. 27 Pressure Hose Connection To Power
Steering Pump
Fig. 28 Power Steering Hose Attachment To
Suspension Cradle
Fig. 29 Power Steering Pressure Hose At Steering
Gear
19 - 20 STEERINGNS
REMOVAL AND INSTALLATION (Continued)

(6) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig.
26).
(7) Install a screw type hose clamp on the power
steering hose to steel tube connection. Tighten the
screw clamp to a torque of 2 N´m (18 in. lbs.).
CAUTION: The protective heat sleeves must cover
the entire rubber hose and hose to tube connection
portion of both the power steering fluid pressure
and return hoses (Fig. 26).
(8) When used, properly position the protective
heat sleeves on the power steering hoses. Then, tie
strap the heat sleeves to the power steering hoses to
keep them in their proper position.
(9) After hoses are installed and power steering
system is filled with fluid and cap is installed on res-
ervoir. Start the engine and check for leaks. (See
Pump Installation).
POWER STEERING FLUID RETURN HOSE
Service all power steering hoses with vehicle raised
on hoist. Cap all open ends of hoses, power steering
pump fittings and steering gear ports to prevent
entry of foreign material into the components.
WARNING: POWER STEERING OIL, ENGINE
PARTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
For part reference and part location for the vehicle
that is being serviced, refer to the following figure
numbers. These show the hose bracket locations,
hose routings and fitting locations by the engine
application of the vehicle. Use these figure numbers
when referring to the removal or installation proce-
dures for the power steering hoses listed below.
REMOVE
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) Raise vehicle See Hoisting, Group 0. Put oil
drain pan under vehicle to catch power steering fluid.
(4) Raise the insulating heat sleeve on the power
steering hoses to expose the hose to steel tube con-
nection. Remove hose clamp where rubber portion of
power steering fluid return hose attaches to steel
tube on suspension cradle (Fig. 30). Remove rubber
hose from steel tube and allow power steering fluid
to drain from pump.(5) Remove the power steering fluid return hose
from the power steering pump return hose fitting.
INSTALL
(1) Using a lint free towel, wipe clean the open
power steering hose ends and power steering pump
fitting.
(2) Attach the power steering return hose to the
fitting on the power steering pump. Route hose
smoothly avoiding tight bends or kinking. Hose must
remain away from the exhaust system and not come
in contact with any unfriendly surfaces of the vehi-
cle.
(3) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig.
30).
(4) Install a screw type hose clamp on the power
steering hose to steel tube connection. Tighten the
screw clamp to a torque of 2 N´m (18 in. lbs.).
CAUTION: The protective heat shield sleeves must
cover the entire rubber hose and hose to tube con-
nection portion of both the power steering fluid
pressure and return hoses (Fig. 30). This is to pre-
vent overheating of the power steering fluid hoses.
(5) When used, position the protective heat sleeves
on the power steering hoses so they cover the connec-
tion to the power steering pump. Then, tie strap the
heat sleeves to the power steering hoses to keep
them in their proper position.
(6) After hoses are installed and power steering
system is filled with fluid and cap is installed on res-
ervoir. Start the engine and check for leaks. (See
Pump Installation).
Fig. 30 Power Steering Return Hose At Steel Tube
NSSTEERING 19 - 21
REMOVAL AND INSTALLATION (Continued)

REMOTE POWER STEERING FLUID RESERVOIR
REMOVE
(1) Remove the filler cap from remote power steer-
ing fluid reservoir (Fig. 31).
(2) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this service man-
ual, for the required lifting procedure to be used for
this vehicle.
(3) Remove at power steering pump, the power
steering fluid hose coming from the power steering
fluid reservoir. Let the power steering fluid drain out
of the reservoir and hose.
(4) Lower vehicle.
(5) Remove the fluid supply hose (Fig. 31) from the
remote power steering fluid reservoir.
(6) Remove the 2 mounting screws (Fig. 31)
attaching the remote fluid reservoir to the inner
fender.
(7) Remove remote reservoir from inner fender.
INSTALL
(1) Install remote power steering fluid reservoir on
inner fender, by first inserting tab on reservoir into
hole in inner fender. Then rotate reservoir so mount-
ing tabs are against inner fender.
(2) Install and securely tighten the 2 reservoir
mounting screws (Fig. 31).
CAUTION: The power steering fluid reservoir to
power steering pump supply hose must be routed
tightly against the strut tower and parallel to the
dash panel. It must also be routed under the wiring
harness and below the drip tube. This will prevent
the hose from coming in contact with the accessory
drive belt. The power steering fluid supply hose
must be located in its correct position by clipping it
to the stud in the strut tower (Fig. 32).(3) Install the fluid supply hose onto the power
steering fluid reservoir fitting (Fig. 31). Install the
hose clamp on the fluid supply hose at the fluid res-
ervoir.Be sure hose clamp in installed past bead
on fluid reservoir fitting.
(4) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this service man-
ual, for the required lifting procedure to be used for
this vehicle.
(5) Install power steering fluid supply hose on
power steering pump. Install the hose clamp on the
fluid supply hose at the power steering pump.Be
sure hose clamp in installed past bead on pump
fitting.
(6) Lower vehicle.
(7) Install routing clip for power steering fluid sup-
ply hose on stud in strut tower (Fig. 32).
(8) Fill the remote fluid reservoir to the proper
level and let the fluid settle for at least two (2) min-
utes.
(9) Start the engine and let run for a few seconds.
Then turn the engine off.
(10) Add fluid if necessary. Repeat the above pro-
cedure until the fluid level remains constant after
running the engine.
(11) Raise the front wheels off the ground.
(12) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
stops.
(13) Add power steering fluid if necessary.
(14) Lower the vehicle and turn the steering wheel
slowly from lock to lock.
(15) Stop the engine. Check the fluid level and
refill as required.
(16) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
Fig. 31 Remote Power Steering Fluid Reservoir
Fig. 32 Power Steering Fluid Hose Routing Clip
19 - 22 STEERINGNS
REMOVAL AND INSTALLATION (Continued)

(28) Remove steering column assembly from vehi-
cle. Use care to avoid damage to paint or interior
trim.
INSTALL
(1) Ensure the plastic mounting capsules (Fig. 22)
are installed in the upper mounting bracket of the
steering column. Mounting capsules must be
installed as shown in (Fig. 22) with the thicker edge
of the capsule facing the top of the steering column.
(2) Install steering column assembly into its open-
ing in instrument panel. Install the steering column
lower bracket so the bracket is squarely installed on
its mounting studs (Fig. 21). Then align and install
steering column upper bracket on its mounting studs
(Fig. 21). Tighten the 4 steering column assembly
mounting nut/washer assemblies to a torque of 12
N´m (105 in. lbs.).
(3) Assemble the steering column shaft coupler
(Fig. 20) onto the steering gear intermediate coupler.
Install steering column coupler to intermediate shaft
retaining pinch bolt (Fig. 20). Tighten the pinch bolt
nut to a torque of 28 N´m (250 in. lbs.). Install safety
pin (Fig. 20) in steering column shaft coupler pinch
bolt.
(4) Install the gear slector cable and its mounting
bracket on the upper mounting bracket of the steer-
ing column (Fig. 17). Install and securely tighten the
mounting bracket attaching bolt.
(5) Install the gear selector cable on the pin of the
gear shifter (Fig. 16).
(6) If the vehicle is equipped with a 3 speed non-
electronic transmission, install the PRNDL actuating
cable on the gear shifter pin after the gear selector
cable is installing (Fig. 15).
(7) If the vehicle is equipped with a 3 speed non-
electronic transmission, install the attaching clip
(Fig. 15) for the PRNDL actuating cable on the steer-ing column/shift cable bracket. Cable guide tube will
bow toward passenger side of vehicle. Verify that
actuating cable is operating correctly, then slip the
loop on the end of the cable over end of pin on shift
lever and install in groove (Fig. 15).
(8) Install the steering column fixed shroud on the
steering column assembly (Fig. 19). Shroud is
mounted to steering column using 2 attaching screws
accessed from top of fixed shroud.
(9) Install the instrument cluster trim bezel (Fig.
18) on the instrument panel. The trim bezel is
mounted to the instrument panel using 2 attaching
screws (Fig. 18) and retaining clips.
(10) Install the 3 wiring harness connectors on the
ignition switch (Fig. 14).
(11) Install the vehicle wiring harness connector
into the key cylinder halo light (Fig. 13).
(12) Install the multi-function switch (Fig. 12) on
the tilt head of the steering column assembly. Then
install screw (Fig. 12) attaching multi-function
switch to tilt head of steering column.
(13) Install the vehicle wiring harness connector
on the multi-function switch (Fig. 11). Be sure latch
on connector is fully engaged with tab on switch.
(14) Install the clock spring on the multi-function
switch.
(15) Install the vehicle wiring harness connector
(Fig. 10) on the clock spring assembly.
(16) Install the lower steering column shroud on
the tilt head of the steering column (Fig. 23). Install
and securely tighten the screw attaching the lower
shroud to the tilt head.
(17) Install the upper steering column shroud on
the tilt head of the steering column (Fig. 24). Install
and securely tighten the 2 screws attaching the
upper shroud to the lower shroud.
Fig. 22 Mounting Capsules Correctly Installed On
Steering Column
Fig. 23 Lower Steering Column Shroud Installed
NSSTEERING 19 - 43
REMOVAL AND INSTALLATION (Continued)

FRONT PUMP OIL SEAL
The pump oil seal can be replaced without remov-
ing the pump and reaction shaft support assembly
from the transaxle case.
REMOVAL
(1) Screw seal remover Tool C-3981-B into seal
(Fig. 7), then tighten screw portion of tool to with-
draw the seal.
INSTALLATION
(1) To install a new seal, place seal in opening of
the pump housing (lip side facing inward). Using Tool
C-4193 and Handle Tool C-4171, drive new seal into
housing until tool bottoms (Fig. 8).
DISASSEMBLY AND ASSEMBLY
TRANSAXLE
Prior to removing any transaxle parts, plug all
openings and clean the unit, preferably with steam.
When disassembling, each part should be washed in
a suitable solvent, then dried with compressed air.
Do not wipe parts with shop towels. All mating sur-
faces in the transaxles are accurately machined;
therefore, careful handling of all parts must be exer-
cised to avoid nicks or burrs.
DISASSEMBLY
Remove all old sealant before applying new seal-
ant.
Use only MopartSilicone Rubber Sealant or equiv-
alent when installing oil pan.
Put sealant on the oil pan flange (Fig. 10) and on
all oil pan bolts (underside of bolt head).
Fig. 7 Remove Pump Oil Seal
Fig. 8 Install Pump Oil Seal
Fig. 9 Transaxle Oil Pan Bolts
Fig. 10 Transaxle Oil Pan
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 21
REMOVAL AND INSTALLATION (Continued)