belt CHRYSLER VOYAGER 2001 Service Manual

INSTALLATION
NOTE: Be sure the copper washer is installed on
end of injector before installing in cylinder head.
(1) Install fuel injector in cylinder head.
(2) Install fuel injector retainer and bolt (Fig. 3).
Torque bolt to 32.4 N´m.
(3) Install fuel injector high pressure line (Fig. 3).(4) Install fuel return line to injector (Fig. 3).
(5) Connect fuel injector electrical connector.
(6) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
(7) Connect negative battery cable.
ACCELERATOR PEDAL
POSITION SENSOR
DESCRIPTION
The accelerator pedal position sensor mounts to
the accelerator pedal bracket (Fig. 4).
OPERATION
The accelerator pedal position sensor contains a
potentiometer that is operated by the accelerator
pedal. As the accelerator pedal is depressed and
released, the sensor provides a variable voltage sig-
nal to the engine control module. This voltage signal
is directly proportional to accelerator pedal position.
When the pedal is fully depressed, the voltage signal
is high.
REMOVAL - PEDAL POSITION SENSOR (LHD)
(1) Disconnect negative battery cable.
(2) Disconnect pedal position sensor electrical con-
nector (Fig. 4).
Fig. 3 FUEL SYSTEM COMPONENTS
1 - FUEL RAIL RETAINING BOLT
2 - FUEL RAIL RETAINING STUD
3 - FUEL RAIL RETURN LINE
4 - FUEL RAIL
5 - FUEL RAIL SUPPLY LINE
6 - IDLER PULLEY
7 - CRANKSHAFT PULLEY
8 - CRANKSHAFT PULLEY RETAINING BOLTS
9 - BELT TENSIONER RETAINING BOLT
10 - BELT TENSIONER
11 - FUEL INJECTOR RETAINER
12 - FUEL INJECTOR RETURN LINE
13 - FUEL INJECTOR RETAINING BOLT
14 - FUEL INJECTORS
15 - FUEL INJECTOR HIGH PRESSURE SUPPLY LINESFig. 4 ACCELERATOR PEDAL POSITION SENSOR
LOCATION (TYPICAL)
1 - ACCELERATOR PEDAL POSITION SENSOR ELECTRICAL
CONNECTOR
2 - ACCELERATOR PEDAL POSITION SENSOR
3 - ACCELERATOR PEDAL
4 - ACCELERATOR PEDAL MOUNTING BRACKET
14a - 12 FUEL INJECTIONRG
FUEL INJECTOR (Continued)

STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION............................1
OPERATION.............................1
DIAGNOSIS AND TESTING..................1
POWER STEERING SYSTEM FLOW AND
PRESSURE TEST........................1STEERING SYSTEM DIAGNOSIS CHARTS....3
SPECIFICATIONS.........................9
SPECIAL TOOLS..........................9
COLUMN...............................10
GEAR.................................17
PUMP.................................24
STEERING
DESCRIPTION - POWER STEERING SYSTEM
This vehicle comes with power steering as stan-
dard equipment and it is the only steering system
available. The power steering system consists of
these major components:
²POWER STEERING PUMP
²POWER STEERING GEAR
²POWER STEERING FLUID RESERVOIR
²POWER STEERING FLUID SUPPLY HOSE
²POWER STEERING FLUID PRESSURE HOSE
²POWER STEERING FLUID RETURN HOSE
²POWER STEERING FLUID COOLER
For information on the first two components, refer
to their respective sections within this service man-
ual group. Information on all other components can
be found in POWER STEERING PUMP.
OPERATION - POWER STEERING SYSTEM
Turning of the steering wheel is converted into linear
(side-to-side) travel through the meshing of the helical
pinion teeth with the rack teeth within the steering
gear. The lateral travel pushes and pulls the tie rods to
change the direction of the vehicle's front wheels.
Power assist steering is provided by a belt driven
rotary type pump. It directs fluid through power
steering fluid hoses to the power steering gear where
it is used to assist the driver's turning effort.
Manual steering control of the vehicle can be main-
tained if power steering assist is lost. However, under
this condition, steering effort is significantly increased.
DIAGNOSIS AND TESTING - POWER STEERING
SYSTEM FLOW AND PRESSURE TEST
ALL ENGINES
The following procedure is to be used to test the
operation of the power steering system on this vehi-
cle. This test will provide the flow rate of the power
steering pump along with the maximum relief pres-sure. This test is to be performed any time a power
steering system problem is present to determine if
the power steering pump or power steering gear is
not functioning properly. The following flow and pres-
sure test is performed using the Power Steering Ana-
lyzer Kit, Special Tool 6815 (Fig. 1), hoses, Special
Tools 6905 and 6959, and fittings from adapter kit,
Special Tool 6893.
Assemble hoses on Power Steering Analyzer, Spe-
cial Tool 6815, as shown. Install Pressure Hose, Spe-
cial Tool 6905 (in 6893 kit), in the inlet fitting on
Power Steering Analyzer. Install Pressure Hose, Spe-
cial Tool 6713 (in 6815 kit) on Pressure Hose, Special
Tool 6905. Install Pressure Hose, Special Tool 6959,
in the outlet fitting on Power Steering Analyzer.
Install the following adapters from Adapter Set,
Special Tool 6893 (Fig. 2), on the analyzer hose ends:
Install Adapter Fitting, Special Tool 6844, on Pres-
sure Hose, Special Tool 6713. Install Adapter Fitting,
Special Tool 6826, on Pressure Hose, Special Tool
6959.
Fig. 1 Power Steering Analyzer With Hoses Installed
1 - OUTLET
2 - SPECIAL TOOL 6815
3 - INLET
RSSTEERING19-1

CAUTION: To prevent personal injury, safety gog-
gles should be worn at all times when performing
any test procedures on the power steering pump or
power steering gear.
The following procedure is to be used to test the
operation of the power steering system on the vehi-
cle.
(1) Check belt tension and adjust as necessary.
(2) Disconnect the power steering fluid pressure
hose from the power steering pump (Fig. 3) (Fig. 4).
(3) Connect Adapter Fitting, Special Tool 6844,
attached to pressure hose from inlet (gauge end) ofPower Steering Analyzer to the pressure fitting on
the power steering pump.
(4) Connect vehicle power steering fluid pressure
hose to Adapter Fitting, Special Tool 6826, which
should be already installed in the outlet hose (valve
end) of Power Steering Analyzer.
(5) Completely open valve on Power Steering Ana-
lyzer.
(6) Start engine and let idle long enough to circu-
late power steering fluid through the analyzer and
hoses, until the air is out of the fluid. Shut off
engine.
(7) Check power steering fluid level and add fluid
as necessary. Start engine again and let idle.
(8) Gauge should read below 862 kPa (125 psi). If
above, inspect the hoses for restrictions and repair as
necessary. The initial pressure should be in the range
of 345-552 kPa (50-80 psi). The flow meter should
read between 1.3 and 1.9 GPM.
CAUTION: The following test procedure involves
testing maximum pump pressure output and flow
control valve operation. Do not leave valve closed
for more than five seconds as the pump could be
damaged.
Fig. 2 Power Steering Analyzer Adapters 6893
Fig. 3 Pressure Hose Connection To Power Steering
Pump - 2.4L
1 - POWER STEERING FLUID RETURN HOSE
2 - POWER STEERING PUMP
3 - POWER STEERING FLUID PRESSURE HOSE
Fig. 4 SUPPLY & PRESSURE HOSES AT PUMP -
3.3L/3.8L
1 - PRESSURE HOSE AND FITTING
2 - SUPPLY HOSE AND CLAMP
3 - POWER STEERING PUMP
19 - 2 STEERINGRS
STEERING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
8. Internal power steering gear
noise.8. Replace power steering gear.
9. Damaged front suspension
crossmember.9. Replace front suspension
crossmember.
10. Stabilizer bar link ball joints
worn.10. Replace stabilizer bar link.
POPPING NOISE 1. Worn outer tie rod. 1. Replace outer tie rod.
CHIRP OR SQUEAL
(POWER STEERING
PUMP)1. Loose power steering pump drive
belt.1. Check and adjust power steering
pump drive belt to specifications or
replace automatic tensioner where
applicable. Replace belt if worn or
glazed.
WHINE, GROWL, MOAN
OR GROAN (POWER
STEERING PUMP)**1. Low fluid level. 1. Fill power steering fluid reservoir to
proper level and check for leaks (make
sure all air is bled from the system
fluid).
2. Power steering hose touching
vehicle body or frame.2. Adjust hose to proper position by
loosening, repositioning, and tightening
fitting to specified torque. Do not bend
tubing. Replace hose if damaged.
3. Extreme wear of power steering
pump internal components.3. Replace power steering pump and
flush system as necessary.
SUCKING AIR SOUND 1. Loose clamp on power steering
fluid return hose.1. Tighten or replace hose clamp.
2. Missing O-Ring on power steering
hose connection.2. Inspect connection and replace
O-Ring as required.
3. Low power steering fluid level. 3. Fill power steering fluid reservoir to
proper level and check for leaks.
4. Air leak between power steering
fluid reservoir and power steering
pump.4. Replace power steering pump (with
reservoir).
SQUEAK OR RUBBING
SOUND1. Steering column shroud rubbing. 1. Realign shrouds as necessary.
2. Steering column shaft rubbing. 2. Move or realign item rubbing shaft.
3. Clockspring noisy. 3. Remove clockspring. Reinstall wheel.
If noise is gone, replace clockspring.
4. Steering gear internally noisy. 4. Replace steering gear.
SCRUBBING OR
KNOCKING NOISE.1. Incorrect tire or wheel size. 1. Replace incorrect size tire or wheel
with size used as original equipment.
2. Interference between steering
gear and other vehicle components.2. Check for bent or misaligned
components and correct as necessary.
3. Steering gear internal stops worn
excessively allowing tires to be
steered excessively far.3. Replace steering gear.
19 - 4 STEERINGRS
STEERING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
5. Lack of lubrication in steering gear
outer tie rod ends.5. Lubricate tie rod ends if they are not a
lubricated-for-life type. If tie rod end is a
lubricated-for-life type, replace tie rod end.
6. Loose power steering pump drive
belt.6. Tighten the power steering pump drive
belt to specifications or replace automatic
tensioner where applicable. If drive belt is
worn or glazed, replace belt.
7. Faulty power steering pump flow
control (Follow Power Steering
System Flow and Pressure Test
procedure).7. Replace power steering pump.
8. Excessive friction in steering
column or intermediate shaft/coupler.8. Isolate and correct condition.
9. Excessive friction in power
steering gear.9. Replace power steering gear.
10. Worn or binding seat and bearing
in front strut assembly.10. Replace seat and bearing in front strut
assembly.
STIFF, HARD TO TURN,
SURGE, MOMENTARY
INCREASE IN EFFORT
WHEN TURNING.1. Tires not properly inflated. 1. Inflate tires to specified pressure.
2. Low power steering fluid level. 2. Add power steering fluid as required to
power steering fluid reservoir to obtain
proper level. Check for leaks.
3. Loose power steering pump drive
belt.3. Tighten the power steering pump drive
belt to specifications or replace automatic
tensioner where applicable. If drive belt is
worn or glazed, replace belt.
4. Lack of lubrication in lower control
arm ball joints.4. Lubricate ball joints if ball joints are not a
lubricated-for-life type ball joint. If ball joint
is a lubricated-for-life ball joint, replace
lower control arm ball joint.
5. Worn or binding lower control arm
ball joint.5. Replace lower control arm ball joint.
6. Low power steering pump
pressure (Follow Power Steering
System Flow and Pressure Test
procedure).6. Replace the power steering pump as
necessary.
7. High internal leak in power
steering gear (Follow Power Steering
System Flow and Pressure Test
procedure).7. Replace power steering gear.
STEERING WHEEL DOES
NOT RETURN TO
CENTER POSITION.1. Tires not inflated properly. 1. Inflate tires to specified pressure.
2. Improper front wheel alignment. 2. Check and adjust wheel alignment as
necessary.
19 - 6 STEERINGRS
STEERING (Continued)

PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION...........................24
OPERATION.............................24
CAUTION...............................25
STANDARD PROCEDURE..................25
POWER STEERING PUMP INITIAL
OPERATION...........................25
REMOVAL..............................25
DISASSEMBLY...........................28
ASSEMBLY.............................28
INSTALLATION...........................29SPECIAL TOOLS.........................30
FLUID
STANDARD PROCEDURE..................30
POWER STEERING FLUID LEVEL
CHECKING............................30
FLUID COOLER
DESCRIPTION...........................30
OPERATION.............................30
REMOVAL..............................31
INSTALLATION...........................31
PUMP
DESCRIPTION
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. The pump used on the
3.3L/3.8L engine is made of aluminum.
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.
OPERATION
The power steering pump is a constant flow rate
and displacement vane type pump. The power steer-
ing pump used on all applications is the Vane-Sub-
merged remote reservoir style power steering pump.
The remote reservoir type pump has the pump
housing and internal components combined with the
fluid housing. It has a remote reservoir for the power
steering fluid supply.Fig. 1 POWER STEERING PUMP (2.4L)
1 - PULLEY
2 - BRACKET
3 - PRESSURE FITTING
4 - RETURN FITTING
5 - SUPPLY FITTING
Fig. 2 POWER STEERING PUMP (3.3L/3.8L)
1 - SUPPLY FITTING
2 - PRESSURE FITTING
3 - PULLEY
19 - 24 PUMPRS

(10) Move the heat sleeve on the power steering
return hose to expose the hose connection at the
pump (Fig. 5). Remove the hose from the power
steering Pump. Allow the remaining power steering
fluid to drain from the power steering pump and res-
ervoir through the removed return hose.
(11) Remove the power steering fluid pressure line
from the power steering pump (Fig. 6). Drain excess
power steering fluid from tube.
(12) Remove the fasteners, then the accessory
drive splash shield.
(13) Remove the adjuster nut attaching rear of
power steering pump to the cast mounting bracket.
(Fig. 7)
(14) Remove the front adjuster nut and the lower
pivot bolt (Fig. 8) attaching power steering pump
bracket to cast bracket.
(15) Remove the drive belt from the power steering
pump pulley.
(16) Remove the power steering pump and the
front bracket from the cast bracket on the engine as
an assembly through the exhaust tunnel.
(17) Remove the 3 bolts attaching the front
bracket to the power steering pump and separate the
power steering pump from the front bracket.
(18) If transferal of the power steering pump pul-
ley is necessary, (Refer to 19 - STEERING/PUMP -
DISASSEMBLY).
REMOVAL - PUMP (3.3L/3.8L ENGINE)
(1) Remove the (-) negative battery cable from the
battery and isolate cable.
(2) Remove the wiper module (unit)(Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - REMOVAL).(3) Raise the vehicle.
(4) Remove the drive belt splash shield.
Fig. 4 Exhaust System - Typical (All Vehicles)
1 - CATALYTIC CONVERTER 4 - SUPPORT - RESONATOR
2 - BAND CLAMP 5 - RESONATOR
3 - SUPPORTS - MUFFLER 6 - MUFFLER
Fig. 5 PRESSURE AND RETURN HOSES - 2.4L
1 - PUMP
2 - RETURN HOSE
3 - ROUTING CLAMPS
4 - PRESSURE FITTING AT GEAR
5 - RETURN FITTING AT GEAR
6 - CRADLE CROSSMEMBER
7 - STEERING GEAR
8 - PRESSURE FITTING AT PUMP
19 - 26 PUMPRS
PUMP (Continued)

(5) Loosen (do not remove) the pump bracket thru-
bolt (#3 in figure) (Fig. 9).
(6) Remove the pressure hose routing bracket bolt
(Fig. 10).
(7) lower the vehicle.
(8) Remove cap from power steering fluid reser-
voir.
(9) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(10) Disconnect the fluid supply hose from the
pump (Fig. 11)(11) Disconnect the pressure hose from the pump
(Fig. 11)
(12) Remove the mounting bolt from the rear of
the pump using care not to lose the spacer between
the pump and bracket (Fig. 9).
(13) Remove the three front mounting bolts
through the pulley (Fig. 9)
(14) Remove the pump through the engine com-
partment rocking it over the aluminum bracket.
Fig. 6 Power Steering Fluid Pressure And Return
Hose
1 - POWER STEERING FLUID RETURN HOSE
2 - POWER STEERING PUMP
3 - POWER STEERING FLUID PRESSURE HOSE
Fig. 7 Power Steering Pump Attaching Nut
1 - POWER STEERING PUMP MOUNTING BRACKET
2 - FRONT SUSPENSION CRADLE
3 - POWER STEERING PUMP
4 - NUT
Fig. 8 PUMP FRONT MOUNTING
1 - NUT
2 - BOLT
3 - PUMP
Fig. 9 PUMP MOUNTING
1 - REAR PUMP BOLT
2 - PUMP MOUNTING BOLT
3 - BRACKET THRU BOLT
4 - PUMP BELT PULLEY
5 - POWER STEERING PUMP
6 - BRACKET
RSPUMP19-27
PUMP (Continued)

DISASSEMBLY - PUMP (PULLEY)
The only serviceable part of the power steering
pump is the pulley. The procedure following is for
removal and installation of the pulley from the pump
once the pump is removed from the vehicle.(1) Remove the power steering pump from the
vehicle. Refer to Removal And Installation in this
section of the service manual.
(2) Remove the pulley from the shaft of the power
steering pump using Puller C-4333 or C-4068 (Fig.
12).
CAUTION: Do not hammer on power steering pump
pulley. This will damage the pulley and the power
steering pump.
(3) Replace pulley if it is found to be bent, cracked,
or loose.
ASSEMBLY - PUMP (PULLEY)
The only serviceable part of the power steering
pump is the pulley. The procedure following is for
removal and installation of the pulley from the pump
once the pump is removed from the vehicle.
(1) Install the pulley with Installer C-4063 (Fig.
13). Do not use the tool adapters.
(2) Ensure that the tool and the pulley remain
aligned with the pump shaft. Prevent the pulley from
being cocked on the shaft.
(3) Install the pulley until it is flush with the end
of the power steering pump shaft (Fig. 14).
(4) Install the power steering pump on the vehicle.
NOTE: Once the pump is installed on the vehicle,
run the engine until it's warm (5 min.) and note any
belt chirp. If chirp exists, move the pulley outward
approximately 0.5 mm (0.020 in.). If noise increases,
press the pulley on 1.0 mm (0.040 in.). Be careful
that the pulley does not contact the pump mounting
bolts.
Fig. 10 PRESSURE HOSE ROUTING CLAMP
1 - PRESSURE HOSE TUBE
2 - STEERING GEAR
3 - CRADLE CROSSMEMBER
4 - DRIVESHAFT
5 - ROUTING CLAMP BRACKET
Fig. 11 SUPPLY & PRESSURE HOSES AT PUMP
1 - PRESSURE HOSE AND FITTING
2 - SUPPLY HOSE AND CLAMP
3 - POWER STEERING PUMP
Fig. 12 Pulley Removal
1 - POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL C-4333
19 - 28 PUMPRS
PUMP (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)