Power steering pump CHRYSLER VOYAGER 2001 Manual PDF

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)

(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)

The cooler used on this vehicle is referred to as a
fluid-to-air type cooler. This means that the air flow
across the tubes (and fines surrounding them) of the
cooler is used to extract the heat from the cooler
which it has absorbed from the power steering fluid
flowing through it. The cooler is placed in series with
the power steering fluid return line, between the
steering gear and the power steering fluid reservoir.
This lowers the temperature of the power steering
fluid prior to it entering the power steering fluid res-
ervoir where it is resupplied to the power steering
pump.
REMOVAL
(1) Using a siphon pump, remove as much fluid as
possible from the power steering fluid reservoir.
(2) Raise vehicle using a frame contact type hoist
or supported using jack stands. See Hoisting in
Lubrication And Maintenance.
(3) Remove the hose clamps at the cooler and
remove the hoses from the cooler inlet and outlet
tubes.
(4) Remove the 2 bolts attaching the power steer-
ing cooler cradle crossmember reinforcement (Fig.
16). Remove the cooler.
INSTALLATION
(1) Install the power steering fluid cooler on the
cradle crossmember reinforcement (Fig. 16). Install
the mounting bolts and tighten to 11 N´m (100 in.
lbs.).
(2) Install power steering fluid hoses on the cooler.
Be sure hose clamps are installed on hose pastthe upset bead on the power steering cooler
tubes.
(3) Lower the vehicle to a point where front tires
are just off the ground.
(4) Perform Power Steering Pump Initial Opera-
tion procedure. (Refer to 19 - STEERING/PUMP -
STANDARD PROCEDURE)
Fig. 16 POWER STEERING COOLER
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
RSPUMP19-31
FLUID COOLER (Continued)

STEERING
TABLE OF CONTENTS
page page
GEAR..................................1PUMP..................................6
GEAR
TABLE OF CONTENTS
page page
GEAR
REMOVAL...............................1INSTALLATION............................4
GEAR
REMOVAL - RHD GEAR
CAUTION: Positioning the steering column in the
locked position will prevent the clockspring from
being accidentally over-extended when the steering
column is disconnected from the intermediate
steering coupler.
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much fluid as
possible from the power steering fluid reservoir.
(3) With the ignition key in the locked position
turn the steering wheel to the left until the steering
wheel is in the locked position.
(4) With the vehicle on the ground, disconnect the
steering column shaft coupler from the steering gear
intermediate coupler (Fig. 1).
(5) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(6) Remove front wheel and tire assemblies.
(7) If equipped, remove hoses at power steering
cooler and allow fluid to drain.
(8) On both sides of vehicle, remove nut attaching
outer tie rod end to steering knuckle (Fig. 2).
Remove nut by holding tie rod end stud with a
socket while loosening and removing nut with
wrench.
(9) Remove both tie rod ends from steering knuck-
les using Puller, Special Tool C-3894±A (Fig. 3).(10) Remove the lower control arm rear bushing
retainer bolts located on each side of each lower con-
trol arm rear bushing.
NOTE: The bolts fastening the cradle crossmember
reinforcement are of two different thread sizes. Note
the location of the various sizes.
Fig. 1 Steering Column Shaft To Intermediate Shaft
Attachment
1 - STEERING COLUMN SHAFT COUPLER
2 - NUT
3 - SAFETY PIN
4 - INTERMEDIATE SHAFT
5 - PINCH BOLT
RGSTEERING19a-1

(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)

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

(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.
RESERVOIR
DESCRIPTION - RESERVOIR (2.5L DIESEL)
All vehicles use a remote mounted power steering
fluid reservoir. The power steering fluid reservoir is
mounted to a bracket on the engine manifold (Fig. 3).
REMOVAL - RESERVOIR (2.5L DIESEL)
(1) Open hood.
(2) Remove engine cover.
(3) Remove the filler cap from remote power steer-
ing fluid reservoir.
(4) Siphon as much fluid as possible from the fluid
reservoir.
(5) Remove the clamp attaching the return hose to
the power steering fluid reservoir. Disconnect hose
from reservoir (Fig. 3).
(6) Remove the clamp attaching the supply hose to
the power steering fluid reservoir. Disconnect hose
from reservoir (Fig. 3).(7)
Press the tang on the reservoir mounting bracket
retaining the reservoir to the bracket, then pull upward
on reservoir and remove it from the bracket.
INSTALLATION - RESERVOIR (2.5L DIESEL)
(1) Align the guide on the rear of the reservoir
with the mounting bracket and push reservoir down-
ward until reservoir clicks into place in the bracket.
(2) Install the supply hose onto the reservoir (Fig.
3). Slide the hose clamp into position on the fluid res-
ervoir and attach it.Be sure hose clamp in
installed past bead on fluid reservoir fitting.
(3) Install the return hose onto the reservoir (Fig.
3). Slide the hose clamp into position on the fluid res-
ervoir and attach it.Be sure hose clamp in
installed past bead on fluid reservoir fitting.
(4)
Fill the fluid reservoir to the proper level with
the correct Mopartpower steering fluid or equivalent.
(5) Start the engine and let run for a few seconds,
then turn the engine off.
(6) Add fluid as necessary.
(7) Install the filler cap.
(8) Install engine cover.
Fig. 2 PUMP AND BRACKETS - 2.5L DIESEL
1 - CAST BRACKET
2 - STAMPED BRACKET
3 - POWER STEERING PUMP
Fig. 3 RESERVOIR AND HOSES - 2.5L DIESEL
1 - POWER STEERING FLUID RESERVOIR
2 - RESERVOIR BRACKET
3 - SUPPLY HOSE BRACKET
4 - RETURN HOSE FROM GEAR
5 - ROUTING CLIP
6 - PRESSURE HOSE TO GEAR
7 - SUPPLY HOSE (PUMP END)
8 - PRESSURE HOSE (PUMP END)
9 - SUPPLY HOSE
10 - RETURN HOSE
RGPUMP19a-7
PUMP (Continued)

EMISSIONS CONTROL
TABLE OF CONTENTS
page page
EMISSIONS CONTROL
DESCRIPTION............................1
OPERATION.............................8EVAPORATIVE EMISSIONS.................10
EXHAUST GAS RECIRCULATION............20
ON-BOARD DIAGNOSTICS.................23
EMISSIONS CONTROL
DESCRIPTION - MONITORED COMPONENT
There are several components that will affect vehi-
cle emissions if they malfunction. If one of these com-
ponents malfunctions the Malfunction Indicator
Lamp (Check Engine) will illuminate.
Some of the component monitors are checking for
proper operation of the part. Electrically operated
components now have input (rationality) and output
(functionality) checks. Previously, a component like
the Throttle Position sensor (TPS) was checked by
the PCM for an open or shorted circuit. If one of
these conditions occurred, a DTC was set. Now there
is a check to ensure that the component is working.
This is done by watching for a TPS indication of a
greater or lesser throttle opening than MAP and
engine rpm indicate. In the case of the TPS, if engine
vacuum is high and engine rpm is 1600 or greater
and the TPS indicates a large throttle opening, a
DTC will be set. The same applies to low vacuum
and 1600 rpm.Any component that has an associated
limp in will set a fault after 1 trip with the malfunc-
tion present.
Refer to the Diagnostic Trouble Codes Description
Charts in this section and the appropriate Power-
train Diagnostic Procedure Manual for diagnostic
procedures.
The following is a list of the monitored compo-
nents:
²Comprehensive Components
²Oxygen Sensor Monitor
²Oxygen Sensor Heater Monitor
²Catalyst Monitor
COMPREHENSIVE COMPONENTS
Along with the major monitors, OBD II requires
that the diagnostic system monitor any component
that could affect emissions levels. In many cases,
these components were being tested under OBD I.
The OBD I requirements focused mainly on testing
emissions-related components for electrical opens and
shorts.However, OBD II also requires that inputs from
powertrain components to the PCM be tested for
rationality, and that outputs to powertrain compo-
nents from the PCM be tested forfunctionality.
Methods for monitoring the various Comprehensive
Component monitoring include:
(1) Circuit Continuity
²Open
²Shorted high
²Shorted to ground
(2) Rationality or Proper Functioning
²Inputs tested for rationality
²Outputs tested for functionality
NOTE: Comprehensive component monitors are
continuous. Therefore, enabling conditions do not
apply.
Input RationalityÐWhile input signals to the
PCM are constantly being monitored for electrical
opens and shorts, they are also tested for rationality.
This means that the input signal is compared against
other inputs and information to see if it makes sense
under the current conditions.
PCM sensor inputs that are checked for rationality
include:
²Manifold Absolute Pressure (MAP) Sensor
²Oxygen Sensor (O2S)
²Engine Coolant Temperature (ECT) Sensor
²Camshaft Position (CMP) Sensor
²Vehicle Speed Sensor
²Crankshaft Position (CKP) Sensor
²Intake Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Ambient/Battery Temperature Sensors
²Power Steering Switch
²Oxygen Sensor Heater
²Engine Controller
²Brake Switch
²Leak Detection Pump Switch
²P/N Switch
²Trans Controls
Output FunctionalityÐPCM outputs are tested
for functionality in addition to testing for opens and
shorts. When the PCM provides a voltage to an out-
RSEMISSIONS CONTROL25-1