belt CHRYSLER VOYAGER 2001 Service Manual

(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)

PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION............................6
REMOVAL...............................6
INSTALLATION............................6RESERVOIR
DESCRIPTION............................7
REMOVAL...............................7
INSTALLATION............................7
PUMP
DESCRIPTION - PUMP (2.5L DIESEL)
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
front lower right corner of the engine (Fig. 2).
The pump has a supply fitting for fluid coming
from the reservoir and a pressure port for exiting
fluid that is headed for the steering gear.
REMOVAL - PUMP (2.5L DIESEL)
(1) Remove the negative (-) battery cable from the
battery and isolate cable.
(2) Remove the fill cap from the power steering
fluid reservoir.
(3) Using a siphon pump, remove as much power
steering fluid as possible from the fluid reservoir.
(4) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(5) Remove the splash shields from below the
engine compartment.
(6) Remove the accessory drive belt from the power
steering pump pulley. (Refer to 7 - COOLING/AC-
CESSORY DRIVE/DRIVE BELTS - REMOVAL)
(7) Disconnect the fluid supply hose from the
pump (Fig. 1).
(8) Disconnect the pressure hose from the pump
(Fig. 1).
(9) Remove the bolt fastening the stamped bracket
on the rear of the pump to the cast bracket (Fig. 2).
(10) Remove the three front mounting bolts
through the pulley.
(11) Remove the pump from the cast bracket and
vehicle.
INSTALLATION - PUMP (2.5L 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. 2). Tighten
the mounting bolt 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 hose
fitting into the pressure port of the power steering
pump (Fig. 1). 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 supply hose on
the power steering pump supply fitting (Fig. 1).Be
sure hose clamp is properly reinstalled.
(6) Install the accessary drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
Fig. 1 POWER STEERING PUMP - 2.5L DIESEL
1 - PRESSURE HOSE
2 - HOSE CLAMP
3 - SUPPLY HOSE
4 - POWER STEERING PUMP
19a - 6 PUMPRG

Before removing the glass, check the availability of
replacement components.
SEATS
Seat modules are made up of a seat frame, seat
cushion, seat back cushion, a covering material, and
the electrical components used for power operation, if
equipped. Some seat systems also contain seat belt
components and supplemental restraint systems.
Seat assemblies transport the occupants in comfort
and safety. Seat assemblies also help position occu-
pants correctly in the event of airbag deployment.
Seat cushions, coverings, and electrical components
are serviceable. Refer to the appropriate group in
this manual.
EXTERIOR COMPONENTS
Exterior sheet metal components make up the
exterior of the vehicle. Some exterior metal systems
are welded assemblies, such as doors and hoods.
Some exterior trim items are made of composite.
The exterior is finished in various metal stampings
and composite moldings. These assemblies give the
vehicle a finished appearance and protect the occu-
pants from the elements. Some components are part
of the energy absorbing system used to protect the
occupants in collisions. The exterior sheet metal is
repairable and adjustable for fit and finish. Welded
and bonded component systems are adjustable as a
system. Trim components made of composite are
stamped with the type of material used.
DaimlerChrysler uses various fasteners to retain
trim items. At times, it is not possible to remove trim
items without damaging the fastener. If it is not pos-
sible to remove an item without damaging a compo-
nent, cut or break the fasteners and use new ones
when installing the component.
SAFETY PRECAUTIONS AND WARNINGS
WARNING:
EYE PROTECTION SHOULD BE USED WHEN SER-
VICING GLASS COMPONENTS. PERSONAL INJURY
CAN RESULT.
USE A OSHA APPROVED BREATHING FILTER
WHEN SPRAYING PAINT OR SOLVENTS IN A CON-
FINED AREA. PERSONAL INJURY CAN RESULT.
AVOID PROLONGED SKIN CONTACT WITH PETRO-
LEUM OR ALCOHOL BASED CLEANING SOLVENTS.
PERSONAL INJURY CAN RESULT.
DO NOT STAND UNDER A HOISTED VEHICLE THAT
IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION:
When holes must be drilled or punched in an innerbody panel, verify depth of space to the outer body
panel, electrical wiring, or other components. Dam-
age to vehicle can result.
Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
Always have a fire extinguisher ready for use when
welding.
Disconnect the negative battery cable clamp when
servicing electrical components that are live when
the ignition is OFF. Damage to electrical system can
result.
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning solvents
on painted or upholstered surfaces. Damage to fin-
ish or color can result.
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
DIAGNOSIS AND TESTING - WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body
drains are clear, and body components are properly
aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
23 - 2 BODYRS
BODY (Continued)

FRONT DOOR BELT DOOR BELT SEAMS (FRONT)
FRONT DOOR BELT DOOR BELT SEAMS (REAR)
RSBODY23-39
BODY (Continued)

BELT TAPPING PLATE - LONG WHEEL BASE ONLY
23 - 104 BODYRS
BODY (Continued)

SPECIFICATIONS -
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
All seat belt anchor bolts 39 29 Ð
Armrest shoulder bolt 29 21 Ð
Bench seat riser bolts 48 35 Ð
Bench seat track nuts 48 35 Ð
Quad bucket seat track to cushion frame bolts 40 30 Ð
Bucket seat back pivot bolts 33 24 Ð
Center seat to seat track bolts 24 17 Ð
Child seat module screws (bench seats) 7 Ð 62
Child seat module screws (quad seats) 13.5 10 Ð
Crossmember to radiator closure panel bolts 28 21 Ð
Door check strap to door end frame 12 Ð 105
Door latch to door end frame bolts 10 Ð 89
Floor latch to seat cushion frame bolts 27 19 Ð
Front cover to seat track screws 4 Ð 32
Front door hinge to hinge pillar bolts 34 25 Ð
Front door hinge to door nuts and bolts 34 25 Ð
Front door latch striker bolts 28 21 Ð
Front/quad seat cushion bolts 28.5 21 Ð
Front seat belt retractor bolts 38 28 Ð
Front seat riser to floor nuts 60 44 Ð
Front seat track cover screws 4 Ð 35
Front seat riser to seat track nuts 81 60 Ð
Front seatback pivot bolts 54 40 Ð
Front seatback recliner nut 12 Ð 105
Front seatback assist strap screws 2.5 Ð 22
Grocery bag holder screws 2 Ð 17
Hinge to liftgate bolts 33 24 Ð
Hood latch to bolts 13.5 10 Ð
Hood latch striker bolts 13.5 10 Ð
Hood hinge to hood bolts 13.5 10 Ð
Liftgate exterior handle outer screws 20 15 Ð
Liftgate exterior handle inner bolts 40 30 Ð
Lifgate hinge to roof header bolts 33 24 Ð
Liftgate latch bolts 16 12 Ð
Liftgate latch striker bolts 28 21 Ð
Liftgate lift motor link to liftgate 28 21 Ð
Liftgate spoiler bolts 9 Ð 80
Lifgate stabalizer wedge striker to D-pillar bolts 3 Ð 30
Luggage rack crossbar fasteners 4 Ð 35
RSBODY23 - 149
BODY (Continued)

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Lumbar support handle screw 1 Ð 9
Pivot bolt to the body half of hood hinge 28 21 Ð
Prop assembly to lifgate bolts 28 21 Ð
Rear door glass to regulator bolt 11 8 Ð
Rear door hinge to B-pillar bolt 28 20 Ð
Rear door hinge to door bolt 28 20 Ð
Rear door latch striker 28 20 Ð
Rear latch to sliding door end frame 28 20 Ð
Rear seat back to seat cushion bolt 27 19 Ð
Recliner to seat back frame 12 9 Ð
Seatback frame upper rail 8 Ð 71
Seatback hinge bolt 48 35 Ð
Seatback hinge cover screws 2.3 Ð 20
Shoulder belt turning loop onto height adjuster 39 29 Ð
Sliding door center hinge adjusting bolt 15 Ð 130
Sliding door glass nuts 3.4 Ð 30
Sliding door latch striker 28 21 Ð
Sliding door to roller arm bracket 12 9 Ð
Storage bin track quide to seat riser 3.5 Ð 31
Support cylinders to liftgate 28 21 Ð
23 - 150 BODYRS
BODY (Continued)

DOOR - FRONT
TABLE OF CONTENTS
page page
APPLIQUE
REMOVAL.............................152
INSTALLATION..........................152
CHECK STRAP
REMOVAL.............................152
INSTALLATION..........................153
DOOR
REMOVAL.............................153
INSTALLATION..........................154
DOOR GLASS
REMOVAL.............................155
INSTALLATION..........................155
FRAME CLOSEOUT MOLDING
REMOVAL.............................155
INSTALLATION..........................156
HINGE
REMOVAL.............................156
INSTALLATION..........................156
LATCH
REMOVAL.............................156
INSTALLATION..........................157
LATCH STRIKER
REMOVAL.............................157INSTALLATION..........................157
LOCK CYLINDER
REMOVAL.............................157
INSTALLATION..........................157
TRIM PANEL
REMOVAL.............................158
INSTALLATION..........................158
TRIM PANEL REFLECTOR
REMOVAL.............................159
INSTALLATION..........................159
WATERSHIELD
REMOVAL.............................159
INSTALLATION..........................159
WINDOW CRANK
REMOVAL.............................159
INSTALLATION..........................159
WINDOW REGULATOR
REMOVAL.............................160
INSTALLATION..........................160
EXTERIOR HANDLE
REMOVAL.............................161
INSTALLATION..........................161
APPLIQUE
REMOVAL
(1) Roll door glass down.
(2) Remove outer door belt molding.
(3) Disengage clips holding front edge of applique
to door frame.
(4) Remove applique from vehicle (Fig. 1) .
INSTALLATION
(1) Position applique on vehicle.
(2)
Hook rear edge of applique over rear edge of door
frame and seat applique bottom edge on sheet metal.
(3) Engage clips to hold front edge of applique to
door frame.
(4) Install outer door belt molding.
CHECK STRAP
REMOVAL
(1) Remove front door watershield. (Refer to 23 -
BODY/DOOR - FRONT/WATERSHIELD -
REMOVAL)
(2) Remove bolts attaching door check strap to
A-pillar (Fig. 4).
(3) Remove nuts attaching check strap to door end
frame (Fig. 2).
(4) Remove check strap from door through speaker
hole.
23 - 152 DOOR - FRONTRS

DOOR GLASS
REMOVAL
(1) Remove watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - REMOVAL)
(2) Remove inner belt molding.(Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - REMOVAL)
(3) Remove outer belt molding.(Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR OUTER BELT
MOLDING - REMOVAL)
(4) Position glass to gain access to front and rear
regulator lift plates through front and rear access
holes in door panel.
(5) Remove clips attaching door glass to regulator
lift plates (Fig. 6).
(6) Remove glass from regulator lift plates.
(7) Disengage glass from glass run weatherstrip.
(8) Insert front of glass between glass run channel
and outer door panel.
(9) Lift glass upward and out of exterior side of
the opening at top of door (Fig. 7).
(10) Remove glass from vehicle.
INSTALLATION
(1) Install clips that attach door glass to regulator
lift plates (Fig. 6).
(2) Place glass in window opening with front
inserted between run channel and outer door panel
(Fig. 7).
(3) Lower glass downward into door.
(4) Insert ends of glass into glass run weatherstrip
channels at front and rear of door.
(5) Place glass in position on regulator lift plates.
(6) Snap glass mounting studs into clips on regu-
lator lift plates.
(7) Install radio speaker, if equipped.
(8) Install outer belt molding. (Refer to 23 - BODY/
WEATHERSTRIP/SEALS/FRONT DOOR OUTER
BELT MOLDING - INSTALLATION)
(9) Install inner belt molding.(Refer to 23 - BODY/
WEATHERSTRIP/SEALS/FRONT DOOR INNER
BELT MOLDING - INSTALLATION)
(10) Verify door glass operation and fit.
(11) Install watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - INSTALLATION)
FRAME CLOSEOUT MOLDING
REMOVAL ± A-PILLAR, HEADER, OR B-PILLAR
(1) Roll door glass down.
(2) Using a hook tool, pull front door frame close-
out molding from window frame channel (Fig. 8).
(3) Remove closeout molding from vehicle.
Fig. 6 Front Door Glass Clips
1 - DOOR GLASS
2 - GLASS LIFT PLATE
3 - CLIP
4 - GUIDE RAIL
5 - REGULATOR LIFT PLATE
Fig. 7 Front Door Glass
1 - DOOR GLASS
2 - FRONT DOOR
3 - GLASS RUN CHANNEL
RSDOOR - FRONT23 - 155

(9) Verify door latch operation.
(10) Install watershield and door trim panel.
TRIM PANEL
REMOVAL
(1) Remove the plug and remove screw attaching
door pull cup to inner door panel.
(2) Remove screws attaching trim panel to door
from below map pocket.
(3) If equipped, remove window crank. (Refer to 23
- BODY/DOOR - FRONT/WINDOW CRANK -
REMOVAL)(4) Remove screw holding door trim to door panel
from behind inside latch release handle .
(5) Disengage clips attaching door trim to door
frame around perimeter of panel.
(6) Lift trim panel upward to disengage flange
from inner belt molding at top of door.
(7) Tilt top of trim panel away from door to gain
access to latch linkage.
(8) Disengage clip attaching linkage rod to inside
latch release handle (Fig. 13).
(9) Separate linkage rod from latch handle.
(10) Disconnect the power door switch, courtesy
lamp, and memory seat switch electrical connectors.
(11) Remove front door trim panel from vehicle.
INSTALLATION
(1) Hold top of trim panel away from door to gain
access to latch linkage.
(2) Place linkage rod in position on latch handle.
(3) Engage clip to hold linkage rod to inside latch
release handle.
(4) Place front door trim panel in position on door.
(5) Install trim panel into inner belt molding at
top of door.
(6) Install clips to attach door trim to door frame
around perimeter of panel.
(7) If equipped, install screw to attach door trim to
door panel behind inside latch release handle.
(8) If equipped, connect power switch into wire
connector.
(9) Place power accessary switch in position on
door trim.
(10) Connect wire connector into memory seat/mir-
ror switch and install switch into trim panel.
Fig. 11 Remove Front Door Lock Cylinder
1 - OUTSIDE DOOR HANDLE
2 - LOCK CYLINDER
3 - CLIP
Fig. 12 Install Front Door Lock Cylinder
1 - CLIP
2 - LINK ARM
3 - DOOR LOCK CYLINDER
4 - OUTSIDE DOOR HANDLE
Fig. 13 Inside Door Handle Linkage
1 - DOOR LATCH HANDLE
2 - DOOR TRIM
3 - LATCH LINKAGE
4 - CLIP
5 - MEMORY SEAT SWITCH
23 - 158 DOOR - FRONTRS
LOCK CYLINDER (Continued)