torque CHRYSLER VOYAGER 2001 Service Manual

CONDITION POSSIBLE CAUSES CORRECTION
3. Lack of lubrication causing binding
in front lower control arm ball joints.3. Lubricate ball joints if ball joints are not a
lubricated for life type of ball joint, then
inspect ball joint for wear, replace lower
control arm as necessary. If ball joint is a
lubricated for life ball joint, replace lower
control arm ball joint.
4. Steering column coupling joints
misaligned.4. Realign steering column coupling joints.
5. Steering wheel rubbing.** 5. Adjust steering column shrouds to
eliminate rubbing condition.
6. Damaged, mis-positioned or
un-lubricated steering column
coupler to dash seal.**6. Replace, reposition, or lubricate dash
seal.
7. Binding pivot bearing in front strut
assembly.7. Replace pivot bearing in front strut
assembly.
8. Binding shaft bearing in steering
column.8. Replace the steering column.
9. Excessive friction in steering
column coupling.9. Replace steering column coupling.
10. Excessive friction in power
steering gear.10. Replace power steering gear.
EXCESSIVE STEERING
WHEEL KICKBACK OR
TOO MUCH STEERING
WHEEL FREE PLAY.1. Air in the fluid of the power
steering system.1. Bleed air from system following the the
power steering pump initial operation
service procedure.*
2. Power steering gear loose on
cradle/crossmember.2. Inspect power steering gear mounting
bolts. Replace as necessary. Tighten to the
specified torque.
3. Steering column coupling or
intermediate shaft worn, broken or
loose.3. Replace steering column coupling or
intermediate shaft.
4. Free play in steering column. 4. Check all components of the steering
column and repair or replace as required.
5. Worn lower control arm ball joints. 5. Replace lower control arm ball joints as
required.
6. Loose steering knuckle-to-ball joint
stud pinch bolt.6. Inspect pinch bolt, replace as necessary,
and tighten to specified torque.
7. Front wheel bearing loose or
worn.7. Replace hub and bearing as necessary.
8. Loose outer tie rod end. 8. Replace outer tie rod end that has
excessive free play.
9. Loose inner tie rod. 9. Replace power steering gear.
10. Defective steering gear rotary
valve.10. Replace power steering gear.
NOTE: * Steering shudder can be expected in new
vehicles and vehicles with recent steering systemrepairs. Shudder should dissipate after the vehicle
has been driven several weeks.
RSSTEERING19-7
STEERING (Continued)

NOTE: ** To evaluate this condition, it may be nec-
essary to disconnect the coupling at the base of the
steering column. Turn the steering wheel and feel or
listen for internal rubbing in steering column. To
avoid damaging the column clockspring, note the
following. Before disconnecting coupling, place
tires in the straight-ahead position and center steer-
ing wheel. Once disconnected, DO NOT rotatesteering wheel more than one revolution in either
direction and place steering wheel in original loca-
tion before reconnecting coupling. If this position is
lost, the steering column clockspring must be
recentered following the procedure found within the
procedure for steering column installation in the
steering column section.
POWER STEERING FLUID
CONDITION POSSIBLE CAUSES CORRECTION
LOW FLUID LEVEL WITH
VISIBLE LEAK.1. Loose power steering hose
fittings.1. Tighten the fitting to its specified torque.
2. Damaged or missing fitting seal,
gasket, or O-ring.2. Replace as necessary.
3. Power steering pump or power
steering gear leaking.3. Repair or replace the leaking component
as required.
AERATED FLUID. 1. Low fluid level.* 1. Fill power steering fluid reservoir to
proper level.
2. Air leak between power steering
fluid reservoir and pump.2. Inspect for proper sealing. Replace the
power steering pump (with reservoir).
3. Cracked power steering pump
housing.3. Replace the power steering pump.
RESERVOIR FLUID
OVERFLOW AND FLUID
THAT IS MILKY IN COLOR1. Water contamination. 1. Drain the power steering fluid from the
system. Flush the system with fresh clean
power steering fluid, drain, then refill to the
proper level.
NOTE: * Extremely cold temperatures may cause
power steering fluid aeration if the power steering
fluid level is low.
19 - 8 STEERINGRS
STEERING (Continued)

SPECIFICATIONS
POWER STEERING FASTENER TORQUE
DESCRIPTION TORQUE
Power Steering Pump:
Flow Control Valve
Pressure Fitting75 N´m (55 ft. lbs.)
Mounting Bolts 54 N´m (40 ft. lbs.)
Rear Bracket To Engine
Mounting Bolts54 N´m (40 ft. lbs.)
Steering Gear:
Mounting Bolts 183 N´m (135 ft. lbs.)
Tie Rod Steering Knuckle
Nut75 N´m (55 ft. lbs.)
Tie Rod Jam Nut 75 N´m (55 ft. lbs.)
Coupling Pinch Bolt 28 N´m (250 in. lbs.)
Power Steering Fluid
Hoses:
Hose Tube Nuts 31 N´m (275 in. lbs.)
Routing Bracket Bolts 23 N´m (200 in. lbs.)
SPECIAL TOOLS
POWER STEERING
Power Steering Analyzer 6815
Adapters, Power Steering Analyzer 6893
HOSE, POWER STEERING ANALYZER 6959
RSSTEERING19-9

(16) Install the steering wheel retaining nut.
Tighten the nut to 61 N´m (45 ft. lbs.)
(17) Install the airbag (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - INSTALLATION).
(18) Install the knee blocker reinforcement (Refer
to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER - INSTALLATION).
(19) Install the parking brake handle link.
(20) Install the knee blocker (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - INSTALLATION).
(21) Install the cluster trim bezel (Refer to 23 -
BODY/INSTRUMENT PANEL/CLUSTER BEZEL -
INSTALLATION).
(22) Install the upper shroud (Refer to 19 -
STEERING/COLUMN/LOWER SHROUD - INSTAL-
LATION).
(23) Install the traction off switch.
(24) Install the lower shroud.
SPECIFICATIONS
COLUMN TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Steering Wheel Retaining
Nut61 45 Ð
Steering Column Mounting
Bracket Attaching Nuts12 Ð 105
Steering Column Coupling
Pinch Bolt28 Ð 250
Steering Column Airbag
Module Attaching Nuts11 Ð 100
KEY/LOCK CYLINDER
DESCRIPTION
The lock cylinder is inserted in the end of the
housing opposite the ignition switch.
OPERATION
The ignition key rotates the cylinder to 5 different
detents (Fig. 7) :
²Accessory
²Off (lock)
²Unlock
²On/Run
²Start
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove steering column cover retaining
screws.
(3) Remove screws holding steering column
shrouds and remove lower shroud.
(4) Place key cylinder in RUN position. Depress
lock cylinder retaining tab on the bottom of the lock
housing and remove key cylinder.
INSTALLATION
(1) Install key in lock cylinder. Turn key to run
position (retaining tab on lock cylinder can be
depressed).
(2) The shaft at the end of the lock cylinder aligns
with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the socket is
in the Run position (Fig. 8) .
Fig. 7 Ignition Lock Cylinder Detents
Fig. 8 Socket in Lock Cylinder Housing
1 - LOCK CYLINDER HOUSING
2 - SOCKET
19 - 14 COLUMNRS
COLUMN (Continued)

(4) Install steering gear assembly on the front sus-
pension cradle. Install the 3 steering gear mounting
bolts and nuts (Fig. 7).
CAUTION: Proper torque on the steering gear to
suspension cradle mounting bolts is very impor-
tant.
(5) Tighten the 3 steering gear to suspension cra-
dle mounting bolts to a torque of 183 N´m (135 ft.
lbs.).
(6) Attach the power steering fluid pressure and
return lines (Fig. 6) to the proper fittings on the
steering gear. Tighten the power steering fluid line
tube nuts to a torque of 31 N´m (275 in. lbs.).
(7) 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. 3), tighten tie rod end
to steering knuckle attaching nut. Then using a
crowfoot and socket (Fig. 10), tighten the tie rod end
attaching nut to a torque of 75 N´m (55 ft. lbs.).
(8) If the vehicle is equipped with All-Wheel-Drive,
install the power transfer unit (Refer to 21 - TRANS-
MISSION/TRANSAXLE/POWER TRANSFER UNIT -
INSTALLATION).
CAUTION: Proper torque on the cradle reinforce-
ment to suspension cradle mounting bolts is very
important.(9) Install the reinforcement on the front suspen-
sion cradle crossmember and install the bolts attach-
ing the reinforcement to the cradle crossmember
(Fig. 5). 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.).
(10) 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.).
(11) Install the two bolts and bushings attaching
the reinforcement and rear of cradle crossmember to
body of vehicle (Fig. 5). Tighten bolts to a torque of
163 N´m (120 ft. lbs.).
(12) Install the power steering cooler hoses on the
cooler inlet and outlet tubes. Install the clamps.
(13) Install the front tire and wheel assemblies on
vehicle. Install the wheel lug nuts and torque to 135
N´m (100 ft. lbs.).
(14) Lower the vehicle to a level were the interior
of vehicle is accessible.
(15) Using the intermediate coupler, turn the front
wheels of the vehicle to the left until the intermedi-
ate coupler shaft is properly aligned with the steer-
ing column coupler. Assemble the steering column
shaft coupler onto the steering gear intermediate
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.).
(16) 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)
(17) Inspect for leaks.
(18) Adjust front toe (Refer to 2 - SUSPENSION/
WHEEL ALIGNMENT - STANDARD PROCEDURE).
SPECIAL TOOLS
POWER STEERING GEARFig. 10 Torquing Tie Rod End Attaching Nut
1 - STEERING KNUCKLE
2 - TIE ROD END
3 - CROWFOOT
4 - SOCKET
5 - TORQUE WRENCH
Puller C-3894A
RSGEAR19-21
GEAR (Continued)

end stationary, tighten tie rod end to steering
knuckle attaching nut (Fig. 12). Then using a crow-
foot and 11/32 socket (Fig. 14), torque tie rod end
attaching nut to 54 N´m (40 ft. lbs.).(4) Tighten tie rod jam nut (Fig. 11) to 55 N´m (75
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. 14 Torquing Tie Rod End Attaching Nut
1 - STEERING KNUCKLE
2 - TIE ROD END
3 - CROWFOOT
4 - SOCKET
5 - TORQUE WRENCH
RSGEAR19-23
OUTER TIE ROD END (Continued)

INSTALLATION - PUMP (2.4L ENGINE)
(1) Install power steering pump back in vehicle
using the reverse order of its removal through the
exhaust tunnel are 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.
(10) When used, properly position the protective
heat sleeve on the power steering return hose. 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 and 1 rear power steering
pump mounting bolts (Fig. 9). Remember to place
spacer between pump and rear mounting bracket
when installing rear mounting bolt. Tighten the
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.
Fig. 13 Pulley Installation
1 - POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL
C-4063±A
Fig. 14 Pulley To Pump Shaft Location
1 - PULLEY
2 - PUMP BODY
3 - PUMP SHAFT
4 - HUB
RSPUMP19-29
PUMP (Continued)

(4) Install the power steering fluid pressure line
into the pressure output fitting of the power steering
pump (Fig. 11). Tighten the pressure line to pump fit-
ting 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. 11).Be sure hose clamps are prop-
erly reinstalled.
(6) Raise the vehicle.
(7) Install the routing clip on the engine for the
pressure hose (Fig. 10).
(8) Tighten the pump thru-bolt (Fig. 9). Tighten to
54 N´m (40 ft. lbs.) torque.
(9) Install the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(10) Install the drive belt splash shield.
(11) Lower the vehicle.
(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.
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.
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. 15).
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 onlyMopart
Power Steering Fluid (MS-5931)or quivalent.
FLUID COOLER
DESCRIPTION
All models of this vehicle 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. 16).
There are two different size coolers offered depending
on options. There is a standard 6-inch and an 8-inch
for vehicles equipped with the heavy duty cooling
package.
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.
Installer C-4063B
Puller C-4333
Fig. 15 POWER STEERING FLUID RESERVOIR
19 - 30 PUMPRS
PUMP (Continued)

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. 8). 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 3 steering gear mounting
bolts and nuts. Tighten the 3 steering gear to sus-
pension cradle mounting bolts to a torque of 183 N´m
(135 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. 5).
(6) Attach the power steering fluid pressure and
return hoses to the proper fittings on the steering
gear (Fig. 5). 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. 6).(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. 2), tighten tie rod end
to steering knuckle attaching nut. Then using a
crowfoot and socket (Fig. 9), 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. 4). 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. 4). Tighten bolts to a torque of
163 N´m (120 ft. lbs.).
Fig. 8 Installing Roll Pin In Intermediate Coupler
1 - INTERMEDIATE COUPLER
2 - SUSPENSION CRADLE
3 - KNURLED NUT
4 - ROLL PIN
5 - STEERING GEAR
Fig. 9 Torquing Tie Rod End Attaching Nut
1 - STEERING KNUCKLE
2 - TIE ROD END
3 - CROWFOOT
4 - SOCKET
5 - TORQUE WRENCH
19a - 4 GEARRG
GEAR (Continued)

(14) If equipped, install the power steering cooler
hoses on the cooler inlet and outlet tubes. Install the
clamps.
(15) 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.).
(16) Lower the vehicle to a level were the interior
of vehicle is accessible (keeping tires off the ground).
(17) Using the intermediate coupler, turn the front
wheels of the vehicle to the left until the intermedi-
ate coupler shaft is properly aligned with the steer-
ing column coupler. Assemble the steering columnshaft coupler onto the steering gear intermediate
coupler (Fig. 1). 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) 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)
(19) Inspect for leaks.
(20) Adjust front wheel toe (Refer to 2 - SUSPEN-
SION/WHEEL ALIGNMENT - STANDARD PROCE-
DURE).
RGGEAR19a-5
GEAR (Continued)