suspension CHRYSLER VOYAGER 2004 Owners Manual

(14) Remove the bolts attaching the cradle cross-
member reinforcement to the front suspension cradle
crossmember (Fig. 6). Remove the 2 bolts fastening
the reinforcement and rear of cradle crossmember to
the body of the vehicle. Remove lower rear bushings,
then the reinforcement.(15) If the vehicle is equipped with All-Wheel-
Drive, remove the power transfer unit as necessary
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT).
(16) Remove tube nuts and power steering pres-
sure and return hoses from the power steering gear
(Fig. 7).
(17) Remove the 3 bolts and nuts mounting the
steering gear to the front suspension cradle (Fig. 8).
NOTE: The next step must be done to allow the
removal of the steering gear from the front suspen-
sion cradle. The steering gear can not be removed
from the vehicle with the intermediate coupler
attached to the steering gear.
(18) Lower steering gear from suspension cradle
enough to allow access to the intermediate coupler
roll pin (Fig. 9). Install Remover/Installer Special
Tool 6831A through the center of the roll pin, secur-
ing with the knurled nut (Fig. 9). Hold threaded rod
stationary while turning nut, this will pull the roll
pin out of the intermediate coupler.
(19) Separate the coupler from the shaft of the
steering gear.
(20) Remove the power steering gear from the
vehicle.
Fig. 6 Cradle Crossmember Reinforcement
Attachment
1 - STEERING GEAR
2 - RIGHT LOWER CONTROL ARM
3 - LEFT LOWER CONTROL ARM
4 - CRADLE CROSSMEMBER REINFORCEMENT
5 - REAR CRADLE CROSSMEMBER ISOLATOR BUSHING
6 - STABILIZER BAR
7 - CRADLE CROSSMEMBER
RSGEAR19-29
GEAR (Continued)

Fig. 7 Hoses To Power Steering Gear - 3.3L/3.8L Engine
1 - RETURN HOSE (TO RESERVOIR)
2 - PRESSURE HOSE (FROM PUMP)
3 - CRADLE CROSSMEMBER
4 - PRESSURE HOSE ROUTING CLAMP
5 - RETURN HOSE ROUTING CLAMP
6 - PRESSURE HOSE TUBE NUT7 - POWER STEERING GEAR
8 - ABS BRACKET
9 - ROUTING CLIP
10 - LEAK DETECTION PUMP FILTER
11 - RETURN HOSE TUBE NUT
12 - ROUTING CLIP
Fig. 8 Steering Gear Mounting To Suspension Cradle
1 - POWER STEERING GEAR
2 - MOUNTING BOLTS (12 MM)
3 - MOUNTING BOLT (14 MM)
4 - FRONT SUSPENSION CRADLE CROSSMEMBER
19 - 30 GEARRS
GEAR (Continued)

REMOVAL - RHD GEAR
(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.
CAUTION: Locking the steering column in the
straight-ahead position will prevent the clockspring
from being accidentally over-extended when the
steering column is disconnected from the interme-
diate steering coupler.
(3) Position the steering wheel in the STRAIGHT-
AHEAD position. Lock the steering wheel in place
using a steering wheel holding tool.
(4) With the ignition key in the locked position
turn the steering wheel to the left until the steering
wheel is in the locked position.
(5) With the vehicle on the ground, disconnect the
steering column shaft coupler from the steering gear
intermediate coupler (Fig. 2).
(6) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(7) Remove front wheel and tire assemblies.
(8) If power steering cooler equipped, remove a
hose at power steering cooler and allow fluid to
drain.
(9) Remove 2 bolts attaching power steering cooler
to cradle crossmember reinforcement (Fig. 3).
(10) On both sides of vehicle, remove nut attaching
outer tie rod end to steering knuckle (Fig. 4).Remove nut by holding tie rod end stud with a
socket while loosening and removing nut with
wrench.
(11) Remove both tie rod ends from steering
knuckles using Puller, Special Tool C-3894±A (Fig. 5).
(12) 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.
(13) Remove the bolts attaching the cradle cross-
member reinforcement to the front suspension cradle
crossmember (Fig. 6). Remove the 2 bolts fastening
the reinforcement and rear of cradle crossmember to
the body of the vehicle. Remove the reinforcement.
(14) If the vehicle is equipped with All-Wheel-
Drive, remove the power transfer unit (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - REMOVAL).
(15) Remove the power steering fluid pressure and
return hoses from the power steering gear (Fig. 10).
(16) Remove the routing clamp bolt securing the
power steering fluid hoses to the rear of the cradle
crossmember (Fig. 11). Allow the hoses to hang down
out of the way.
(17) Remove the heat shield from the steering gear
(Fig. 10).
(18) Remove the 2 bolts and nuts mounting the
steering gear to the front suspension cradle.
Fig. 9 Removing Roll Pin From Intermediate Coupler
1 - INTERMEDIATE COUPLER
2 - KNURLED NUT
3 - SUSPENSION CRADLE
4 - REMOVER SPECIAL TOOL 6831A
5 - STEERING GEAR
6 - NUT
7 - ROLL PIN
8 - THREADED ROD
Fig. 10 RHD Gear Heat Shield And Hose Fittings
1 - HEAT SHIELD
2 - CRADLE CROSSMEMBER
3 - RETURN HOSE FITTING
4 - PRESSURE HOSE FITTING
5 - POWER STEERING GEAR
RSGEAR19-31
GEAR (Continued)

NOTE: The next step must be done to allow the
removal of the steering gear from the front suspen-
sion cradle. The steering gear cannot be removed
from the vehicle with the intermediate coupler
attached to the steering gear.
(19) Lower steering gear from suspension cradle
enough to allow access to the intermediate coupler
roll pin (Fig. 9). Install Remover/Installer, Special
Tool 6831A, through the center of the roll pin, secur-
ing with the knurled nut (Fig. 9). Hold threaded rod
stationary while turning nut, this will pull the roll
pin out of the intermediate coupler.
(20) Separate the coupler from the steering gear
shaft.
(21) Remove the power steering gear from the
vehicle.
INSTALLATION
INSTALLATION - LHD GEAR
(1) Install the power steering gear up in the front
suspension cradle, leaving room to install intermedi-
ate 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. 12). Hold threaded rod station-
ary while turning nut, this will pull the roll pin into
the intermediate coupler.
CAUTION: Proper torque on the steering gear to
suspension cradle mounting bolts is very impor-
tant.
(4) Install steering gear on the front suspension
cradle. Install the 3 steering gear mounting bolts and
nuts (Fig. 8). Tighten the 3 mounting bolts to the fol-
lowing torque values:
²14 mm bolt ± 183 N´m (135 ft. lbs.) torque
²12 mm bolt ± 95 N´m (70 ft. lbs.) torque
(5) Attach the power steering fluid pressure and
return hoses to the correct ports on the power steer-
ing gear (Fig. 7). Tighten the hose tube nuts at the
gear to a torque of 31 N´m (275 in. lbs.).
(6) If the vehicle is equipped with All-Wheel-Drive,
install the power transfer unit as necessary (Refer to
21 - TRANSMISSION/TRANSAXLE/POWER
TRANSFER UNIT).
Fig. 11 RHD Power Steering Gear - 2.5L Diesel
Shown
1 - RETURN HOSE
2 - PRESSURE HOSE
3 - CRADLE CROSSMEMBER
4 - POWER STEERING GEAR
5 - RETURN HOSE FITTING
6 - PRESSURE HOSE FITTING
7 - HOSE ROUTING CLAMP
Fig. 12 Installing Roll Pin In Intermediate Coupler
1 - INTERMEDIATE SHAFT COUPLER
2 - SUSPENSION CRADLE CROSSMEMBER
3 - KNURLED NUT
4 - ROLL PIN
5 - POWER STEERING GEAR
19 - 32 GEARRS
GEAR (Continued)

CAUTION: Proper torque on the cradle reinforce-
ment to suspension cradle mounting bolts is very
important.
(7) Install the reinforcement on the front suspen-
sion cradle crossmember and install the bolts attach-
ing the reinforcement to the cradle crossmember
(Fig. 6). Tighten the M-14 size bolts to a torque of
153 N´m (113 ft. lbs.). Tighten the M-12 size bolts to
a torque of 106 N´m (78 ft. lbs.).
(8) Install the lower control arm rear bushing
retainer bolts (M-10 size) through reinforcement on
each side of each lower control arm rear bushing.
Tighten bolts to a torque of 61 N´m (45 ft. lbs.).
(9) Install the two bolts and bushings attaching
the reinforcement and rear of cradle crossmember to
body of vehicle (Fig. 6). Tighten bolts to a torque of
163 N´m (120 ft. lbs.).
(10) Install outer tie rod end into steering knuckle.
Start outer tie rod to steering knuckle attaching nut
onto stud of tie rod end. While holding stud of tie rod
end stationary using a socket (Fig. 4), tighten tie rod
end to steering knuckle attaching nut. Then using a
crowfoot and socket (Fig. 13), tighten the tie rod end
attaching nut to a torque of 75 N´m (55 ft. lbs.).
(11) Install leak detection pump on cradle cross-
member reinforcement. (Refer to 25 - EMISSIONS
CONTROL/EVAPORATIVE EMISSIONS/LEAK
DETECTION PUMP - INSTALLATION)
(12) Install the power steering fluid cooler on the
cradle crossmember reinforcement (Fig. 3). Install
the mounting bolts and tighten to 11 N´m (100 in.
lbs.). When installing mounting bolts, include pres-
sure hose routing clamp.(13) Reconnect previously disconnected hose at
power steering cooler and install clamp.
(14) Install the front tire and wheel assemblies on
vehicle. Install the wheel lug nuts and torque to 135
N´m (100 ft. lbs.).
(15) Install front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - INSTALLATION)
(16) Lower the vehicle to a level where the interior
of vehicle is accessible.
(17) With the wheels pointed approximately
STRAIGHT-AHEAD, align the intermediate shaft
with the steering column coupler. Assemble the steer-
ing column shaft coupler onto the steering gear inter-
mediate 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.).
(18) Remove the steering wheel holding tool.
(19) Fill and bleed the power steering system
using the Power Steering Pump Initial Operation
Procedure. (Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE)
(20) Inspect system for leaks.
(21) Adjust front toe (Refer to 2 - SUSPENSION/
WHEEL ALIGNMENT - STANDARD PROCEDURE).
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. 12). 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 2 steering gear mounting
bolts and nuts. Tighten the M-14 size steering gear
to suspension cradle mounting bolt to a torque of 183
N´m (135 ft. lbs.). Tighten the M-12 size steering
gear to suspension cradle mounting bolt to a torque
of 95 N´m (70 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. 10).
(6) Attach the power steering fluid pressure and
return hoses to the proper fittings on the steering
Fig. 13 Torquing Tie Rod End Attaching Nut
1 - STEERING KNUCKLE
2 - TIE ROD END
3 - CROWFOOT
4 - SOCKET
5 - TORQUE WRENCH
RSGEAR19-33
GEAR (Continued)

gear (Fig. 10). 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. 11).
(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. 4), tighten tie rod end
to steering knuckle attaching nut. Then using a
crowfoot and socket (Fig. 13), 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. 6). 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. 6). Tighten bolts to a torque of
163 N´m (120 ft. lbs.).
(14) If power steering cooler equipped, install the
previously disconnected power steering cooler hose on
the cooler. Install the clamp.
(15) If power steering cooler equipped, install the
power steering fluid cooler on the cradle crossmem-
ber reinforcement (Fig. 3). Install the mounting bolts
and tighten to 11 N´m (100 in. lbs.).
(16) 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.).
(17) Lower the vehicle to a level were the interior
of vehicle is accessible (keeping tires off the ground).
(18) With the wheels pointed approximately
STRAIGHT-AHEAD, align the intermediate shaft
with the steering column coupler. Assemble the steer-
ing column shaft coupler onto the steering gear inter-
mediate 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.).
(19) Remove the steering wheel holding tool.
(20) 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)
(21) Inspect for leaks.
(22) Adjust front wheel toe (Refer to 2 - SUSPEN-
SION/WHEEL ALIGNMENT - STANDARD PROCE-
DURE).
SPECIAL TOOLS
POWER STEERING GEAR
OUTER TIE ROD
REMOVAL
(1) Loosen inner tie rod to outer tie rod jam nut
(Fig. 14).
(2) Remove nut attaching outer tie rod end to
steering knuckle (Fig. 15). The nut is to be removed
from tie rod end by holding tie rod end stud with a
11/32 socket while loosening and removing nut with a
wrench.
(3) Remove the tie rod end stud from steering
knuckle arm, using Remover, Special Tool C-3894±A
(Fig. 16).
(4) Remove outer tie rod end by un-threading it
from the inner tie rod.
INSTALLATION
NOTE: Before installing the outer tie rod, make sure
the jam nut is on inner tie rod (Fig. 14).
Puller C-3894A
Remover/Installer Steering Shaft Roll Pin 6831A
19 - 34 GEARRS
GEAR (Continued)

(1) Install outer tie rod onto inner tie rod.
(2) Do not tighten jam nut.
(3) Install tie rod end into the 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, tighten tie rod end to steering
knuckle attaching nut (Fig. 15). Then using a crow-
foot and 11/32 socket (Fig. 17), torque tie rod end
attaching nut to 75 N´m (55 ft. lbs.).
(4) Tighten tie rod jam nut (Fig. 14) to 75 N´m (55
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 Inner To Outer Tie Rod Jam Nut
1 - INNER TIE ROD SERRATION
2 - OUTER TIE ROD JAM NUT
3 - OUTER TIE ROD END
4 - INNER TIE ROD
5 - STEERING KNUCKLE
Fig. 15 Tie Rod End Attaching Nut (Typical)
1 - TIE ROD END
2 - STEERING KNUCKLE
3 - WRENCH
4 - SOCKET
5 - TIE ROD END STUD
Fig. 16 TIE ROD REMOVAL WITH TOOL C-3894-A
1 - OUTER TIE ROD
2 - SPECIAL TOOL C-3894-A
3 - STEERING KNUCKLE
Fig. 17 Torquing Tie Rod End Attaching Nut
1 - STEERING KNUCKLE
2 - TIE ROD END
3 - CROWFOOT
4 - SOCKET
5 - TORQUE WRENCH
RSGEAR19-35
OUTER TIE ROD (Continued)

(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.
Fig. 5 Pressure And Return Hoses - 2.4L
1 - POWER STEERING PUMP
2 - RETURN HOSE (HEAT SLEEVE COVERED)
3 - ROUTING CLAMPS
4 - PRESSURE HOSE TUBE NUT
5 - RETURN HOSE TUBE NUT
6 - CRADLE CROSSMEMBER
7 - POWER STEERING GEAR
8 - PRESSURE HOSE
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 - ADJUSTER NUT
Fig. 8 Pump Front Mounting
1 - ADJUSTER NUT
2 - PIVOT BOLT
3 - PUMP
RSPUMP19-39
PUMP (Continued)

INSTALLATION
(1) Install the power steering fluid cooler on the
cradle crossmember reinforcement (Fig. 18). 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 past
the 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)
HOSE - POWER STEERING
PRESSURE
REMOVAL
REMOVAL - 2.4L ENGINE
NOTE: Before proceeding, review all WARNINGS
and CAUTIONS. (Refer to 19 - STEERING/PUMP -
WARNING)(Refer to 19 - STEERING/PUMP - CAU-
TION)
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(5) Place an oil drain pan under vehicle to catch
power steering fluid.
(6) Back out pressure hose tube nut at power
steering pump pressure fitting and remove hose from
pump (Fig. 19).
(7) Remove bolt attaching right routing clamp to
front suspension cradle crossmember (Fig. 19).
Remove pressure hose from clamp.
(8) Back out pressure hose tube nut at power
steering gear and remove hose from gear (Fig. 19).
(9) Remove power steering fluid pressure hose
from vehicle.
REMOVAL - 3.3L/3.8L ENGINE
NOTE: Before proceeding, review all WARNINGS
and CAUTIONS. (Refer to 19 - STEERING/PUMP -
WARNING)(Refer to 19 - STEERING/PUMP - CAU-
TION)
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(5) Remove two bolts securing pressure hose rout-
ing clamps to suspension cradle crossmember and
steel reinforcement (Fig. 20).
(6) Place an oil drain pan under vehicle to catch
draining power steering fluid.
(7) Disconnect pressure hose at power steering
gear (Fig. 20).
Fig. 19 PRESSURE AND RETURN HOSES - 2.4L
1 - POWER STEERING PUMP
2 - RETURN HOSE (HEAT SLEEVE COVERED)
3 - ROUTING CLAMPS
4 - PRESSURE HOSE TUBE NUT
5 - RETURN HOSE TUBE NUT
6 - CRADLE CROSSMEMBER
7 - POWER STEERING GEAR
8 - PRESSURE HOSE
RSPUMP19-45
FLUID COOLER (Continued)

CAUTION: Use care not to bend tube ends of the
power steering hoses when installing. Leaks and
restrictions may occur.
CAUTION: Power steering fluid hoses must remain
away from the exhaust system and must not come
in contact with any unfriendly surfaces on the vehi-
cle.
(4) Route hose up behind engine toward pump
avoiding tight bends or kinking.
(5) Install power steering pressure hose end into
pump pressure outlet fitting (Fig. 21). Thread tube
nut into outlet fitting, but do not tighten at this time.
(6) Attach pressure hose routing bracket to engine
(Fig. 21). Tighten bolt to 23 N´m (200 in. lbs.) torque.
(7) Tighten hose tube nut at pump outlet fitting to
31 N´m (275 in. lbs.) torque.
(8) Route hose behind cradle crossmember and
start hose end into gear port. Do not tighten hose
tube nut at this time.
(9) Attach hose to suspension cradle crossmember
and steel reinforcement using two routing clamps
and bolts (Fig. 20). Tighten clamp bolt at steel rein-
forcement to 11 N´m (100 in. lbs.) torque. Tighten
clamp bolt at cradle crossmember to 23 N´m (200 in.
lbs.) torque.
(10) Tighten hose tube nut at power steering gear
port to 31 N´m (275 in. lbs.) torque.
(11) Install front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - INSTALLATION)
(12) Lower vehicle.
(13) Fill and bleed the power steering system
using the Power Steering Pump Initial Operation
Procedure. (Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE)
(14) Inspect system for leaks.
HOSE - POWER STEERING
RETURN
REMOVAL
REMOVAL - 2.4L ENGINE
NOTE: Before proceeding, review all WARNINGS
and CAUTIONS. (Refer to 19 - STEERING/PUMP -
WARNING)(Refer to 19 - STEERING/PUMP - CAU-
TION)
(1) Remove cap from power steering fluid reser-
voir.(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(5) Place an oil drain pan under vehicle to catch
power steering fluid.
(6) Cut tie-strap securing insulating heat sleeve to
power steering fluid return hose near power steering
pump. Pull back heat sleeve to expose hose clamp.
(7) Remove clamp, then return hose from power
steering pump (Fig. 19).
(8) Remove 2 bolts attaching power steering cooler
to cradle crossmember reinforcement (Fig. 23).
(9) Remove bolts attaching routing clamps to front
suspension cradle crossmember (Fig. 19). Remove
return hose from clamps.
(10) Back out return hose tube nut at power steer-
ing gear and remove hose (Fig. 19).
REMOVAL - 3.3L/3.8L ENGINE
NOTE: Before proceeding, review all WARNINGS
and CAUTIONS. (Refer to 19 - STEERING/PUMP -
WARNING)(Refer to 19 - STEERING/PUMP - CAU-
TION)
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Place an oil drain pan under vehicle to catch
any draining power steering fluid.
(4) Remove clamp attaching return hose to power
steering fluid reservoir. Disconnect hose from reser-
voir (Fig. 21).
(5) Follow return hose downward and open
retainer at ABS bracket (Fig. 20). Remove hose tube
from retainer.
(6) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(7) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(8) Remove bolt securing return hose routing
clamp to suspension cradle crossmember (Fig. 20).
(9) Remove 2 bolts attaching power steering cooler
to cradle crossmember reinforcement (Fig. 23).
(10) Disconnect return hose at power steering gear
(Fig. 20).
19 - 48 PUMPRS
HOSE - POWER STEERING PRESSURE (Continued)