Chrysler Caravan/Voyager/Town and Country 1996-1999

Power Steering Pump

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REMOVAL & INSTALLATION



2.4L (VIN B) Engine

See Figures 1, 2, 3, 4, 5, 6 and 7



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Fig. Fig. 1: Power steering components (2.4L engine)

  1. Disconnect and isolate the negative battery cable from the battery.
  2.  
  3. Remove the power steering drive belt. It is not necessary to remove the belt from the engine.
  4.  
  5. Loosen, but do not remove the nut securing the front bracket for the power steering pump to the aluminum mounting bracket.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Disconnect the wiring harness connector to the oxygen sensor which is accessible through the oxygen sensor wiring harness grommet in the vehicle floor pan.
  10.  
  11. Remove the catalytic converter from the exhaust manifold and remove all exhaust system hangers and isolators from the exhaust system brackets. Move the exhaust system out of the way as far rearward and to the left as possible to provide access to the power steering pump.
  12.  
  13. Place a drain pan under the power steering pump. Remove the power steering fluid return line hose on the front suspension cradle. Allow the fluid to drain from the pump and hose.
  14.  



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Fig. Fig. 2: After the belt is removed, loosen (but do not remove) the power steering pump-to-mounting bracket nut



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Fig. Fig. 3: Exhaust system positioned for pump removal

  1. Remove the accessory drive belt splash shield.
  2.  
  3. Disconnect the power steering remote reservoir supply hose from the fitting on the power steering pump. Allow fluid to drain from the hose.
  4.  
  5. Remove power steering fluid pressure line from the power steering pump and drain any excess power steering fluid.
  6.  
  7. Remove the power steering fluid return hose from the power steering pump.
  8.  
  9. Remove the nut securing the rear of the power steering pump to the cast mounting bracket.
  10.  
  11. Loosen the 3 bolts securing the power steering pump to the front mounting bracket and then remove the nut and bolt mounting the front of the power steering pump to the cast mounting bracket.
  12.  
  13. Remove the power steering pump and front bracket as an assembly from the cast bracket.
  14.  
  15. Remove the 3 mounting bolts securing the bracket to the power steering pump and separate the bracket from the power steering pump.
  16.  
  17. Remove the power steering pump from the vehicle. Transfer any parts from the power steering pump to the new replacement power steering pump.
  18.  



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Fig. Fig. 4: Drive belt splash shield mounting detail



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Fig. Fig. 5: Disconnect the pressure and return lines from the pump

To install:
  1. Install the power steering pump into the vehicle and position the front of the pump onto the cast mounting bracket. Loosely install mounting nut to secure the pump in place.
  2.  
  3. Install the front mounting bracket on the power steering pump and loosely install the 3 mounting bolts, then install the nut and bolt securing the front bracket to the cast bracket.
  4.  
  5. Torque the 3 power steering pump mounting bracket bolts to 40 ft. lbs. (54 Nm).
  6.  
  7. Install the high pressure fluid line to the pump output fitting. Torque the high pressure line-to-power steering pump fitting to 275 inch lbs. (31 Nm). Be sure to inspect the pressure line O-ring for any damage before connecting the pressure line to the steering pump.
  8.  
  9. Install the low pressure power steering fluid hose to the power steering pump low pressure fitting. Be sure the hose clamps are properly reinstalled and hoses are clear of the accessory drive belts.
  10.  
  11. Install the power steering fluid reservoir supply hose to the power steering pump fluid fitting. Be sure all hoses are clear of any accessory drive belts and hose clamps correctly installed.
  12.  
  13. Install the power steering drive belt.
  14.  
  15. Install the accessory drive belt splash shield.
  16.  
  17. Install the hose on the power steering fluid return line on the front suspension cradle. Be sure the hose clamps and heat shield tubes are correctly reinstalled.
  18.  
  19. Reconnect the exhaust pipe to the exhaust manifold. Install the hangers and isolators onto the exhaust system brackets. Torque the nuts and bolts to 250 inch lbs. (28 Nm).
  20.  
  21. Reconnect the wiring harness connectors to the oxygen sensor. Install the wiring harness grommet into the vehicle floor pan.
  22.  



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Fig. Fig. 6: After the pump and lines are disconnected and drained of excess fluid, remove the adjustment bracket nut



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Fig. Fig. 7: Unbolt the pump from the bracket, followed by unbolting the bracket

  1. Remove the drain pan and lower the vehicle.
  2.  
  3. Torque the top mounting nut and bottom mounting bolt on the power steering pump front mounting bracket to 40 ft. lbs. (54 Nm).
  4.  
  5. Refill the power steering pump reservoir with the correct amount of clean power steering fluid.
  6.  
  7. Reconnect the negative battery cable. Bleed the power steering system.
  8.  
  9. Run the engine and check the system for leaks and proper steering operation.
  10.  

3.0L (VIN 3) Engine

See Figures 8, 9 and 10



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Fig. Fig. 8: Power steering pump mounting detail (3.0L engine)

  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Remove the accessory drive belt. The belt does not have to be removed from the engine.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Disconnect the wiring harness connector to the oxygen sensor which is accessible through the oxygen sensor wiring harness grommet in the vehicle floor pan.
  8.  
  9. Remove the catalytic converter from the exhaust manifold and remove all exhaust system hangers and isolators from the exhaust system brackets. Move exhaust system out of the way as far rearward and to the left as possible to provide access to the power steering pump.
  10.  
  11. Place a drain pan under the power steering pump. Remove the power steering fluid return line hose on the front suspension cradle. Allow the fluid to drain from the pump and hose.
  12.  
  13. Remove the accessory drive belt splash shield.
  14.  
  15. Disconnect the power steering remote reservoir supply hose from the fitting on the power steering pump. Allow fluid to drain from the hose.
  16.  
  17. Remove power steering fluid pressure line from the power steering pump and drain any excess power steering fluid.
  18.  
  19. Remove the power steering fluid return hose from the power steering pump.
  20.  
  21. Remove the rear support bracket mounted behind the power steering pump to the engine block.
  22.  
  23. Remove the 2 mounting bolts that secure the pump to the alternator/power steering pump and belt tensioner mounting bracket.
  24.  
  25. Remove the power steering pump and pulley assembly out from the vehicle. Transfer all required parts from the pump to the new replacement pump before installation.
  26.  

To install:
  1. Position the front of the power steering pump up onto the mounting bracket. Torque the 2 power steering pump-to-mounting bracket bolts to 40 ft. lbs. (54 Nm).
  2.  
  3. Install the rear power steering pump-to-engine block support bracket. Torque the 2 support bracket mounting bolts to 40ft. lbs. (54 Nm). Install the nut to the mounting stud behind the pump and torque to 40 ft. lbs. (54 Nm).
  4.  
  5. Install the high pressure fluid line to the pump output fitting. Torque the high pressure line-to-power steering pump fitting to 275 inch lbs. (31 Nm). Be sure to inspect the pressure line O-ring for any damage before connecting the pressure line to the steering pump.
  6.  
  7. Install the low pressure power steering fluid hose to the power steering pump low pressure fitting. Be sure the hose clamps are properly reinstalled and hoses are clear of the accessory drive belts.
  8.  
  9. Install the accessory drive belt.
  10.  
  11. Install the hose on the power steering fluid return line on the front suspension cradle. Be sure the hose clamps and heat shield tubes are correctly reinstalled.
  12.  
  13. Reconnect the exhaust pipe to the exhaust manifold. Install the hangers and isolators onto the exhaust system brackets. torque the nuts and bolts to 250 inch lbs. (28 Nm).
  14.  
  15. Reconnect the wiring harness connectors to the oxygen sensor. Install the wiring harness grommet into the vehicle floor pan.
  16.  
  17. Install the accessory drive belt splash shield.
  18.  
  19. Remove the drain pan and lower the vehicle.
  20.  
  21. Refill the power steering pump reservoir with the correct amount of clean power steering fluid.
  22.  
  23. Reconnect the negative battery cable. Bleed the power steering system.
  24.  
  25. Run the engine and check the system for leaks and proper steering operation.
  26.  

3.3L (VIN R) and 3.8L (VIN L) Engines


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Fig. Fig. 9: Rear support bracket mounting detail (3.3 & 3.8L engines)



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Fig. Fig. 10: Power steering pump mounting detail (3.3 & 3.8L engines)

  1. Remove and isolate the negative battery cable.
  2.  
  3. Raise and safely support the vehicle. Place a drain pan under the power steering pump.
  4.  
  5. Disconnect the wiring harness connector to the oxygen sensor which is accessible through the oxygen sensor wiring harness grommet in the vehicle floor pan.
  6.  
  7. Remove the catalytic converter from the exhaust manifold and remove all exhaust system hangers and isolators from the exhaust system brackets. Move exhaust system out of the way as far rearward and to the left as possible to provide access to the power steering pump.
  8.  
  9. Remove the power steering fluid return line hose on the front suspension cradle. Allow the fluid to drain from the pump and hose.
  10.  
  11. Remove the accessory drive belt splash shield.
  12.  
  13. Remove accessory drive belt.
  14.  
  15. Disconnect the power steering remote reservoir supply hose from the fitting on the power steering pump. Allow fluid to drain from the hose.
  16.  
  17. Remove power steering fluid pressure line from the power steering pump and drain any excess power steering fluid.
  18.  
  19. Remove the power steering fluid return hose from the power steering pump.
  20.  
  21. Remove the rear support bracket mounted behind the power steering pump to the engine block.
  22.  
  23. Remove the 3 mounting bolts that secure the pump to the alternator/power steering pump and belt tensioner mounting bracket.
  24.  
  25. Remove the power steering pump and pulley assembly from the vehicle. Transfer all required parts from the pump to the new replacement pump before installation.
  26.  

To install:
  1. Position the front of the power steering pump up onto the mounting bracket. Torque the 3 power steering pump-to-mounting bracket bolts to 40 ft. lbs. (54 Nm).
  2.  
  3. Install the rear power steering pump-to-engine block support bracket. Torque the support bracket mounting bolts to 40 ft. lbs. (54 Nm). Install the nut to the mounting stud behind the pump and torque to 40 ft. lbs. (54 Nm).
  4.  
  5. Install the high pressure fluid line to the pump output fitting. Torque the high pressure line-to-power steering pump fitting to 275 inch lbs. (31 Nm). Be sure to inspect the pressure line O-ring for any damage before connecting the pressure line to the steering pump.
  6.  
  7. Install the low pressure power steering fluid hose to the power steering pump low pressure fitting. Be sure the hose clamps are properly reinstalled and hoses are clear of the accessory drive belts.
  8.  
  9. Install the accessory drive belt.
  10.  
  11. Install the hose on the power steering fluid return line on the front suspension cradle. Be sure the hose clamps and heat shield tubes are correctly reinstalled.
  12.  
  13. Reconnect the exhaust pipe to the exhaust manifold. Install the hangers and isolators onto the exhaust system brackets. Torque the nuts and bolts to 250 inch lbs. (28 Nm).
  14.  
  15. Reconnect the wiring harness connectors to the oxygen sensor. Install the wiring harness grommet into the vehicle floor pan.
  16.  
  17. Install the accessory drive belt splash shield.
  18.  
  19. Remove the drain pan and lower the vehicle.
  20.  
  21. Refill the power steering pump reservoir with the correct amount of clean power steering fluid.
  22.  
  23. Reconnect the negative battery cable. Bleed the power steering system.
  24.  
  25. Run the engine and check the system for leaks and proper steering operation.
  26.  

BLEEDING




CAUTION
The power steering fluid level should be checked with the engine OFF to prevent injury from moving components. Power steering oil, engine components and exhaust system may be extremely hot if the engine has been running. Do not start the engine with any loose or disconnected hoses or allow hoses to touch a hot exhaust manifold or catalyst.

In all power steering pumps, use only MOPAR® Power Steering Fluid or equivalent. DO NOT use any type of automatic transmission fluid in the power steering system.

Wipe the filler cap clean, then check the fluid level. The dipstick should indicate FULL COLD when the fluid is at normal room temperature of approximately 70-80°F.

  1. Fill the power steering pump fluid reservoir to the proper level. Allow the fluid to settle for at least 2 minutes.
  2.  
  3. Start the engine and let run for a few seconds. Turn the engine OFF.
  4.  
  5. Add fluid if necessary. Repeat this procedure until the fluid level remains constant after running the engine.
  6.  
  7. Raise and safely support the vehicle so the front wheels of the vehicle are off the ground.
  8.  
  9. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine OFF.
  10.  
  11. Add power steering fluid if necessary.
  12.  
  13. Lower the vehicle and turn the steering wheel slowly from lock to lock.
  14.  
  15. Turn OFF the engine. Check the fluid level and refill as required.
  16.  
  17. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure.
  18.  

 
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