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EPL_19
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Datasheet EPL_19 Datasheet

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Page 1
PL STEERING 19 - 1
STEERING
CONTENTS
page page
GENERAL INFORMATION .................. 1
POWER STEERING PUMP ................ 10
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
STEERING SYSTEM AND COMPONENT
GENERAL INFORMATION
STEERING SYSTEM AND COMPONENT DESCRIPTION
This vehicle comes with power steering as stan­dard equipment and is the only steering system available.
The power steering system consists of these six major components. Power Steering Pump, Power Steering Gear, Power Steering Reservoir, Power Steering Supply and Pressure Hoses, and Power Steering Fluid Return Hose. Turning of the steering wheel is converted into linear travel through the meshing of the helical pinion teeth with the rack teeth. Power assist steering is provided by an open center, rotary type control valve. It is used to direct oil from the power steering pump to either side of the integral steering rack piston.
Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle. As steering effort increases as in a turn, the torsion bar twists, causing relative rotary motion between the rotary valve body and valve spool. This movement directs oil behind the integral rack piston, which in turn, builds up hydraulic pressure and assists in the turn­ing effort.
STEERING COLUMN ..................... 35
STEERING GEAR ....................... 27
DIAGNOSIS AND TESTING
STEERING SYSTEM DIAGNOSIS CHARTS .... 1
DIAGNOSIS AND TESTING
STEERING SYSTEM DIAGNOSIS CHARTS

STEERING NOISE

There is some noise in all power steering systems. One of the most common is a hissing sound evident at standstill parking. Hiss is a very high frequency noise similar to that experienced while slowly closing a water tap. The noise is present in every valve and results in high velocity fluid passing valve orifice edges. There is no relationship between this noise and performance of the steering. Hiss may be expected when steering wheel at end of travel or slowly turning at standstill.
Page 2
19 - 2 STEERING PL
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
Objectionable Hiss Or Whistle 1. Damaged or mispositioned
steering column coupler to dash panel seal.
2. Noisy valve in power steering gear.
Rattle Or Clunk 1. Steering gear loose on front
suspension crossmember.
2. Front suspension crossmember to frame bolts or studs loose.
3. Loose tie rod (outer or inner). 3. Check tie rod pivot points for
4. Loose lower control arm to front suspension crossmember bolts.
5. Loose strut assembly to body attaching bolts or nuts.
6. Power steering fluid pressure hose touching the body of the vehicle.
7. Noise internal to power steering gear.
8. Damaged front suspension crossmember.
1. Check for proper seal between steering column coupler and dash seal.
2. Replace steering gear assembly.
1. Check steering gear to front suspension crossmember mounting bolts. Tighten to the specified torque if found to be loose.
2. Tighten the front suspension crossmember attaching bolts or studs to the specified torque.
wear. Replace worn/loose parts as required.
4. Tighten control arm mounting bolts to the specified torques.
5. Check upper strut mount to body attaching bolts or nuts for looseness. If required, tighten to the specified torques.
6. Adjust hose to proper position by loosening, repositioning, and tightening fitting to specified torque. Do not bend tubing.
7. Replace steering gear assembly.
8. Replace front suspension crossmember.
Chirp or squeal (in the area of the power steering pump). Particularly noticeable at full wheel travel and during standstill parking.
1. Loose power steering pump drive belt.
1. Adjust power steering pump drive belt to specified tension.
Page 3
PL STEERING 19 - 3
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
Power steering pump growl results from the development of high pressure fluid flow. Normally this noise should not be high enough to be objectionable. Abnormal situations, such as a low oil level causing aeration or hose touching the vehicle body, can create a noise level that could bring complaints.
Whine Or Growl (Pump Noise) 1. Low fluid level. 1. Fill power steering fluid reservoir
to proper level and perform leakage diagnosis. (Recheck fluid level after power steering fluid is free of air.)
2. Power steering hose touching vehicle body or frame.
3. Extreme wear of power steering pump internal parts.
2. Reposition power steering hose. Replace hose if tube ends are bent.
3. Replace power steering pump and flush system.
Sucking Air Sound 1. Loose clamp on power steering
fluid low pressure hose.
2. Missing O-Ring on power steering hose connection.
3. Low power steering fluid level 3. Fill power steering fluid reservoir
4. Air leak between power steering fluid reservoir and power steering pump.
SQUEAK OR RUBBING SOUND 1. Sound coming from steering
column.
2. Sound internal to steering gear. 1. Replace steering gear assembly.
SCRUBBING OR KNOCKING SOUND
1. Incorrect tire size. 1. Verify that tire size on vehicle is
2. Check clearance between tires and other vehicle components, through the full travel of the suspension.
3. Check for interference between steering gear and other components.
4.Incorrect steering gear supplied. 4. Replace steering gear with correct
1. Tighten or replace hose clamp.
2. Inspect connection and replace O-Ring as required.
to proper level and perform leakage diagnosis.
4. Inspect and or replace power steering fluid reservoir as required.
1.Check for squeak in steering column. Inspect for contact between shroud, intermediate shaft, column, and steering wheel. Realign if necessary.
2. Check for lack or grease on steering column dash panel to lower coupler seal.
the same as originally supplied.
2. Correct as necessary.
3.Correct as necessary.
steering gear for specific vehicle.
Page 4
19 - 4 STEERING PL
DIAGNOSIS AND TESTING (Continued)

BINDING STICKING SEIZED

CONDITION POSSIBLE CAUSES CORRECTION
CATCHES, STICKS IN CERTAIN POSITIONS OR IS DIFFICULT TO TURN.
1. Low power steering fluid level. 1. Fill power steering fluid reservoir to specified level and perform leakage diagnosis.
2. Tires not inflated to specified
pressure.
3. Lack of lubrication in front
suspension control arm ball joints.
4. Lack of lubrication in front
suspension outer tie rod ends.
5. Loose power steering pump drive
belt.
6. Faulty power steering pump flow
control. (Verify cause using Power Steering Pump Test Procedure.)
7. Excessive friction in steering
column or intermediate shaft.
8. Steering column coupler binding. 8. Realign the steering column to
9. Binding upper strut bearing. 9. Correct binding condition in strut
10 Excessive friction in steering gear.
2. Inflate tires to the specified pressure.
3. 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 ball joint or control arm.
4. 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.
5. Tighten the power steering pump drive belt to the specified tension. See accessory drive in service manual.
6. Replace power steering pump.
7. Correct condition. (See Steering Column Service Procedure)
eliminate the binding condition. bearing.
10 Replace steering gear assembly.
Page 5
PL STEERING 19 - 5
DIAGNOSIS AND TESTING (Continued)

SHAKE SHUDDER VIBRATION

CONDITION POSSIBLE CAUSES CORRECTION
VIBRATION OF THE STEERING WHEEL AND/OR DASH DURING DRY PARK OR LOW SPEED STEERING MANEUVERS.
1. Air in the fluid of the power
steering system.
2. Tires not properly inflated. 2. Inflate tires to the specified
3. Excessive engine vibration. 3. Ensure that the engine is running
4. Loose tie rod end. 4. Check that the inner to outer tie
5.Overcharged air conditioning
system.

LOW ASSIST, NO ASSIST, HARD STEERING

CONDITION POSSIBLE CAUSES CORRECTION
STIFF, HARD TO TURN, SURGES, 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
3. Loose power steering pump drive
belt.
4. Lack of lubrication in control arm
ball joints.
5. Low power steering pump
pressure. (Verify using Power Steering System Test Procedure)
6. High internal leak in steering gear
assembly.
1. Steering shudder can be expected in new vehicles and vehicles with recent steering system repairs. Shudder should improve after the vehicle has been driven several weeks.
pressure. properly. rod jam nut for is tight. If required,
tighten the jam nut to the specified torque.
5.Check air conditioning pump head pressure. (See Air Conditioning Refrigerant System Diagnosis)
required to power steering fluid reservoir to obtain proper level. Perform leakage diagnosis on power steering system.
3. Adjust the power steering pump drive belt to the specified tension. If drive belt is defective replace and correctly tension.
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 ball joint or control arm.
5. Verify cause using the Power Steering System Test Procedure. Replace the power steering pump if necessary.
6. Check steering system using the Power Steering System Test Procedure. If steering gear is defective replace steering gear.
Page 6
19 - 6 STEERING PL
DIAGNOSIS AND TESTING (Continued)

POOR RETURN TO CENTER

CONDITION POSSIBLE CAUSES CORRECTION
STEERING WHEEL DOES NOT WANT TO RETURN TO CENTER POSITION.
1. Tires not
inflated to specified pressure.
2. Improper front wheel alignment. 2. Check and adjust as necessary.
3. Lack of lubrication in front
suspension control arm ball joints.
4. Steering column U-joints
misaligned.
5.
Mispositioned dash cover.
6. Steering wheel rubbing. 6. Adjust steering column shrouds to
7. Damaged, mis-positioned or
un-lubricated steering column coupler to dash seal.
8. Binding upper strut bearing. 8. Correct
9. Tight shaft bearing
in steering column assembly.
10. Excessive friction in steering
column coupler.
11. Excessive friction in steering
gear.
1. Inflate tires to specified pressure.
3. Lubricate ball joints if ball joints are not a lubricated for life type of ball joint. If ball joint is a lubricated for life ball joint, replace ball joint or control arm.
4. Realign steering column U-joints.
5. Reposition dash cover. To
evaluate items 6 and 7, disconnect the intermediate shaft. Turn the steering wheel and feel or listen for internal rubbing in steering column.
eliminate rubbing condition.
7. Determine condition which exists and correct.
binding condition in strut bearing.
9. Replace the steering column assembly.
10. Replace steering column coupler.
11. Replace steering gear.
Page 7
PL STEERING 19 - 7
DIAGNOSIS AND TESTING (Continued)

LOOSE STEERING

CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE STEERING WHEEL KICKBACK OR TO MUCH STEERING WHEEL FREE PLAY.
1. Air in the fluid of the power
steering system.
2. Steering gear loose on front
suspension crossmember.
3. Worn, broken or loose steering
column to steering gear coupler.
4. Free play in steering column. 4.Check components of the steering
5. Loose front suspension control
arm ball joints.
6. Loose steering knuckle to ball
joint stud pinch bolt.
7. Front wheel bearings loose or
worn.
8. Loose outer tie rod ends. 8. Check free play of outer tie rod
9. Loose inner tie rod ends. 9. Replace steering gear assembly.
10 Defective steering gear rotary valve.
1. Fill power steering fluid reservoir to the specified level. Perform procedure to bleed the air out of the power steering system. Perform leakage diagnosis.
2. Check steering rear to front suspension crossmember mounting bolts. Tighten to specified torque if found to be loose.
3. Check for worn universal joint, broken isolator or loose fasteners.
system and repair or replace as required.
5. Check and or replace the ball joint or control arm as required.
6. Check pinch bolts and tighten if required to specified torque.
7. Tighten hub nut to specified torque or replace with new parts as necessary.
ends and replace if required.
10. Replace steering gear assembly.
Page 8
19 - 8 STEERING PL
DIAGNOSIS AND TESTING (Continued)

VEHICLE LEADS TO THE SIDE

CONDITION POSSIBLE CAUSES CORRECTION
STEERING WHEEL DOES NOT WANT RETURN TO CENTER POSITION.
STEERING WHEEL HAS FORE AND AFT LOOSENESS.
1. Radial tire lead. 1.Rotate tires as recommended in the Tire And Wheel Group of this service manual.
2. Front suspension misaligned. 2. Align the front suspension as required. Refer to the Wheel Alignment Procedure in the Suspension Group of this service manual for the required wheel alignment procedure.
3. Wheel braking. 3. Check for dragging brakes. Refer to the procedures in the Brake Group of this service manual.
4. Unbalanced steering gear valve.
(If this is the cause, the steering efforts will be very light in direction of lead and heavier in the opposite direction.
1. Steering wheel to steering column
shaft retaining nut not properly tightened and torqued.
2. Steering column lower bearing
spring retainer slipped on steering column shaft.
4. Replace steering gear.
1. Tighten the retaining nut to its specified torque specification.
2. Replace steering column.
Page 9
PL STEERING 19 - 9
DIAGNOSIS AND TESTING (Continued)

POWER STEERING FLUID LEAK

CONDITION POSSIBLE CAUSES CORRECTION
LOW FLUID LEVEL WITH: NO VISIBLE SIGNS OF A LEAK ON THE STEERING GEAR, POWER STEERING PUMP, FLOOR OR ANYWHERE ELSE. LOW FLUID LEVEL WITH: VISIBLE LEAK ON STEERING GEAR, POWER STEERING PUMP, FLOOR OR ANYWHERE ELSE.
1. Overfilled power steering pump
fluid reservoir.
2. Power steering hose connections
at the power steering pump or steering gear.
3. Power steering pump or power
steering gear leaking.

FOAMY OR MILKY POWER STEERING FLUID

CONDITION POSSIBLE CAUSES CORRECTION
AERATION AND OVERFLOW OF FLUID.
1. Air leaks. 1. Check for an air leak into the
2. Low fluid level. 2. Extremely cold temperatures may
3. Cracked power steering pump
housing.
4. Water contamination. 4. Drain the power steering fluid
1. Adjust the power steering fluid fill to the correct level.
2. Check for loose fittings and if found, tighten the fitting to its specified torque. If fittings are tight examine the fittings for damaged or missing O-ring seals and replace as required.
3. Identify the location of the leak and repair or replace the component as required. Refer to Power Steering Pump and/or Power Steering Gear in this group of the service manual for required procedures.
power steering system as described under Sucking Air Diagnosis and correct condition.
cause power steering fluid aeration if the power steering fluid is low. Add power steering fluid as required to bring level up to specification.
3. Remove power steering pump from vehicle and inspect the power steering pump housing for cracks. If a defect in the housing is found, replace the power steering pump.
from the system if there is evidence of contamination. Then refill the system with fresh clean power steering fluid.
Page 10
POWER STEERING PUMP FLUID SUP-
POWER STEERING PUMP DISCHARGE
FITTING
PLY FITTING
POWER STEERING PUMPHOUSINGPOWER STEERINGPUMP SHAFT
19 - 10 STEERING PL

POWER STEERING PUMP

INDEX
page page

DESCRIPTION AND OPERATION

POWER STEERING PUMP ............... 10
DIAGNOSIS AND TESTING
POWER STEERING SYSTEM TEST
SERVICE PROCEDURES
POWER STEERING PUMP FLOW CONTROL
POWER STEERING PUMP INITIAL OPERATION
...................................... 12
POWER STEERING PUMP SUCTION PORT
POWER STEERING SYSTEM FLUID LEVEL
REMOVAL AND INSTALLATION
POWER STEERING FLUID PRESSURE
DESCRIPTION AND OPERATION
POWER STEERING PUMP
On all vehicles equipped with power steering, the hydraulic pressure for operation of the power steer­ing gear is provided by a belt driven power steering pump (Fig. 1). The TTA power steering pump is a constant flow rate and displacement, vane type pump.
Fig. 1 TTA Power Steering Pump Assembly
In the event of a power steering pump drive belt failure, manual steering control of the vehicle can still be maintained. However, under these conditions, steering effort will be significantly increased.
POWER STEERING FLUID RESERVOIR ..... 22
POWER STEERING FLUID RETURN HOSE . . . 16 POWER STEERING FLUID SUPPLY HOSE
RESERVOIR TO POWER STEERING PUMP . 18
POWER STEERING PRESSURE SWITCH .... 13
POWER STEERING PUMP (ALL ENGINES) . . . 19
DISASSEMBLY AND ASSEMBLY
POWER STEERING PUMP DRIVE PULLEY . . . 23 POWER STEERING PUMP MOUNTING
SPECIFICATIONS
POWER STEERING PUMP FASTENER
POWER STEERING PUMP FLOW
SPECIAL TOOLS
POWER STEERING PUMP ............... 26
All vehicles equipped with power steering use a remote mounted reservoir for the power steering fluid. The power steering fluid remote reservoir is mounted to the rear of the cylinder head on the pas­senger side of the vehicle.
The service procedures for the TTA power steering pump are limited to the areas and components listed below. No repair procedures are to be done on
internal components of the TTA power steering pumps.
• Repair of power steering fluid leaks from areas of the power steering pump sealed by O-rings is allowed (See Pump Leak Diagnosis). However power steering pump shaft seal leakage will require replacement of the pump.
• Power steering fluid reservoirs, related compo­nents and attaching hardware.
• Power steering fluid reservoir filler cap/dipstick assemblies.
Because of unique shaft bearings, flow control lev­els or pump displacements, power steering pumps may be used only on specific vehicle applications. Be sure that all power steering pumps are only replaced with a pump that is the correct replacement for that specific application.
Hydraulic pressure is provided for operation of the power steering gear by the belt driven power steering pump id (Fig. 1). It is a constant displacement, vane type pump. The power steering pump is connected to the steering gear by a power steering fluid pressure hose and return hose.
Page 11
PRESSURE HOSETO POWERSTEERING GEAR SPECIALTOOL 6815POWER STEER-ING PUMPTO POWERSTEERINGPUMP
SPECIAL TOOL6815 ADAPTER FIT-TINGS
PL STEERING 19 - 11
DESCRIPTION AND OPERATION (Continued)
Rectangular pumping vanes in the shaft driven rotor, move power steering fluid from the intake to the cam ring pressure cavities of the power steering pump. As the rotor begins to turn, centrifugal force throws the vanes against the inside surface of the cam ring to pickup residual oil. This oil is then forced into the high pressure area. As more oil is picked up by the vanes, the additional oil is forced into the cav­ities of the thrust plate through two crossover holes in the cam ring and pressure plate. The crossover holes empty into the high pressure area between the pressure plate and the housing end cover.
As the high pressure area is filled, oil flows under the vanes in the rotor slots, forcing the vanes to fol­low the inside surface of the cam ring. As the vanes reach the restricted area of the cam ring, oil is forced out from between the vanes. When excess oil flow is generated during high-speed operation, a regulated amount of oil returns to the pump intake side through a flow control valve. The flow control valve reduces the power required to drive the pump and holds down temperature build-up.
When steering conditions exceed maximum pres­sure requirements, such as when the wheels are turned against the stops. The pressure built up in the steering gear exerts pressure on the spring end of the flow control valve. The high pressure lifts the relief valve ball from its seat and allows oil to flow through a trigger orifice located in the outlet fitting. This reduces pressure on the spring end of the flow control valve which then opens and allows the oil to return to the intake side of the pump. This action limits maximum pressure output of the pump to a safe level.
Under normal power steering pump operating con­ditions, pressure requirements of the pump are below maximum, causing the pressure relief valve to remain closed.
Fig. 2 Power Steering Pump Flow/Pressure Tester

POWER STEERING PUMP FLOW AND PRESSURE TEST PROCEDURE

(1) Check power steering pump drive belt tension
and adjust as necessary.
(2) Disconnect power steering fluid pressure hose, at power steering pump. Use a container for dripping fluid.
(3) Connect Pressure Gauge, Special Tool from kit 6815 (Fig. 3) to both hoses using adapter fittings. Connect spare pressure hose, to power steering pump pressure hose banjo fitting.

DIAGNOSIS AND TESTING

POWER STEERING SYSTEM TEST PROCEDURE

The following procedure can be used to test the operation of the power steering system on the vehi­cle. This test will provide the flow rate of the power steering pump along with the maximum relief pres­sure. 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 pressure and flow test is performed using Pressure/Flow Tester, Special Tool 6815 (Fig. 2).
Fig. 3 Power Steering Pump Flow/Pressure Tester
Connected To Power Steering Pump
(4) Completely open valve on Special Tool 6815
(Fig. 3).
(5) Start engine and let idle long enough to circu­late power steering fluid through flow/pressure test and get air out of fluid. Then shut off engine.
(6) Check power steering fluid level, and add fluid as necessary. Start engine again and let idle.
(7) Pressure gauge should read below 862 kPa (125 psi), if above, inspect the hoses for restrictions and repair as necessary. The initial pressure reading
Page 12
19 - 12 STEERING PL
DIAGNOSIS AND TESTING (Continued)
should be in the range of 345-552 kPa (50-80 psi). The flow meter should read between 1.3 and 1.4 GPM
CAUTION: The following test procedure involves testing power steering pump maximum pressure output and flow control valve operation. Do not leave valve closed for more than 5 seconds as the pump could be damaged.
(8) Close valve fully three times and record high-
est pressure indicated each time. All three read-
ings must be above specifications and within 345 kPa (50 psi) of each other.
NOTE: Power steering pump maximum relief pres­sure is 8240 to 8920 kPa (1195 to 1293 psi.).
• If power steering pump pressures above specifi­cations but not within 345 kPa (50 psi) of each other, then replace power steering pump.
• If pressures within 345 kPa (50 psi) of each other but below specifications, then replace power steering pump.
CAUTION: Do not force the pump to operate against the stops for more than 5 seconds at a time because, pump damage will result.
(9) Open test valve. Turn steering wheel to the extreme left and right positions until against the stops, recording the highest indicated pressure at each position. Compare pressure gauge readings to power steering pump specifications. If highest output pressures are not the same against either stop, the steering gear is leaking internally and must be replaced.

POWER STEERING PUMP INITIAL OPERATION

CAUTION: The fluid level should be checked with engine off to prevent injury from moving compo­nents. Use only MoparT Power Steering Fluid. Do not use automatic transmission fluid. Do not over­fill.
Wipe filler cap clean, then check the fluid level. The dipstick should indicate FULL COLD when the fluid is at normal temperature of approximately 21°C to 27°C (70°F to 80°F).
(1) Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes.
(2) Start the engine and let run for a few seconds. Then turn the engine off.
(3) Add fluid if necessary. Repeat the above proce­dure until the fluid level remains constant after run­ning the engine.
(4) Raise the front wheels off the ground.
(5) Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops.
(6) Add power steering fluid if necessary.
(7) Lower the vehicle and turn the steering wheel slowly from lock to lock.
(8) Stop the engine. Check the fluid level and refill as required.
(9) If the fluid is extremely foamy, allow the vehi­cle to stand a few minutes and repeat the above pro­cedure.

POWER STEERING PUMP FLOW CONTROL VALVE SEAL

The power steering pump does not require removal from the engine for removal and replacement of the flow control valve fitting O-Ring.

SERVICE PROCEDURES

POWER STEERING SYSTEM FLUID LEVEL CHECK

WARNING: FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING PARTS. DO NOT USE AUTOMATIC TRANS­MISSION FLUID IN THE POWER STEERING SYS­TEM. DO NOT OVERFILL THE POWER STEERING SYSTEM.
Wipe reservoir filler cap free of dirt. Then check fluid level. The dipstick should indicate COLD when fluid is at normal ambient temperature, approxi­mately 21°C to 27°C (70°F to 80°F). In all pumps add fluid as necessary, use only Mopar Power Steering
Fluid, or equivalent. DO NOT USE ANY TYPE OF AUTOMATIC TRANSMISSION FLUID.
REMOVE
(1) Remove the power steering fluid pressure hose
from the power steering pump pressure fitting (Fig.
4). (2) Remove the flow control valve fitting from the
power steering pump housing (Fig. 5). Prevent flow
control valve and spring from sliding out of housing bore.
(3) Remove and discard O-ring seal from fitting.

INSTALL

(1) If necessary, clean and install flow control
valve and spring in pump housing bore.
(2) Install new O-ring seal on fitting. (3) Install fitting in pump housing and tighten to
75 N·m (55 ft. lbs.)
(4) Install power steering fluid pressure hose on
flow control valve fitting.
Page 13
POWER STEER-ING PUMP POWER STEERING PRES-SURE HOSEPOWER STEER-ING PUMPBRACKET LOCATING PIN BANJO BOLT
POWER STEERINGPUMPPOWER STEERING PUMPDISCHARGE AND FLOWCONTROL FITTING
POWER STEERING FLUIDSUPPLY HOSE RADIATOR HOSE
POWER STEERING PUMPBOLT
POWER STEERING PUMP SUCTION
PORT FITTING
PL STEERING 19 - 13
SERVICE PROCEDURES (Continued)
Fig. 4 Pressure Hose Attachment To Power Steering
Pump
Fig. 5 Pump Discharge And Flow Control Valve
Fitting
(5) Position locating pin on power steering pres­sure hose banjo fitting so it is against power steering pump mounting bracket (Fig. 4). While holding locat­ing pin against power steering pump bracket, torque banjo bolt to 34 N·m (25 ft. lbs.).

POWER STEERING PUMP SUCTION PORT SEAL

The power steering pump does not require removal from the engine for removal and replacement of the suction port O-Ring seal.

REMOVE

(1) Remove power steering fluid supply hose from power steering pump suction port fitting (Fig. 6).
(2) Remove bolt (Fig. 6) attaching power steering pump suction port fitting to the power steering pump.
(3) Remove the suction port fitting (Fig. 6) from the power steering pump.
Fig. 6 Power Steering Pump Suction Port Fitting
(4) Remove and discard O-ring seal from suction
port fitting.

INSTALL

(1) Install new O-ring seal on suction fitting.
(2) Install suction port fitting in power steering pump. Install and securely tighten the suction port fitting attaching bolt.
(3) Install power steering fluid supply hose on suc­tion port fitting, being sure hose clamp is installed on hose past upset bead on suction port fitting.

REMOVAL AND INSTALLATION

POWER STEERING PRESSURE SWITCH

On vehicles equipped with power steering, a power steering pressure switch is used to improve the vehi­cle’s idle quality. The pressure switch improves vehi­cle idle quality, by controlling engine idle speed when required.
The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed is increased. This increase in engine idle speed compensates for the additional load, thus maintain­ing the require engine idle speed and idle quality.
The power steering pressure switch (Fig. 7) is mounted directly to the power steering gear on vehi­cle’s requiring its usage.
Page 14
VEHICLE WIR-ING HARNESS STEERING GEARVEHICLE WIRING HAR-NESS CONNECTOR FRONT SUSPENSIONCROSSMEMBER POWER STEERINGFLUID PRESSURESWITCH
POWER STEERING PRES-SURE HOSE ROUTING BRACKETPOWER STEERING RETURNHOSE BOLT
19 - 14 STEERING PL
REMOVAL AND INSTALLATION (Continued)

REMOVE

CAUTION: When removing and installing the power steering pressure switch, the use of a 7/8 inch deep well socket is required. The deep well socket will prevent damage to the plastic, electrical connector area, of the power steering pressure switch.
(1) Disconnect negative battery cable from the neg­ative post of the battery. Be sure cable is isolated from negative post on battery.
(2) Raise vehicle.
(3) Locate power steering pressure switch (Fig. 7) on back side of power steering gear.
CAUTION: Do not use automatic transmission fluid in power steering system. Only use MoparT, Power Steering Fluid, or equivalent.
(3) Fill power steering reservoir to correct fluid
level.
(4) Connect negative cable back on negative post of
battery.
(5) Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in sys­tem. Stop engine, check fluid level, and inspect sys­tem for leaks. See Checking Fluid Level.

POWER STEERING FLUID PRESSURE HOSE

CAUTION: Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent entry of foreign material into the compo­nents.
WARNING: POWER STEERING OIL, ENGINE PARTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DIS­CONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
Fig. 7 Power Steering Pressure Switch Location On
Steering Gear
(4) Remove vehicle wiring harness connector (Fig.
7), from power steering pressure switch. (5) Remove power steering pressure switch, from
power steering gear.

INSTALL

CAUTION: When installing the power steering pressure switch in the steering gear, do not exceed the torque specification shown in step 1 below. Over-torquing will result in stripping the threads out of the power steering pressure switch port on the steering gear.
(1) By hand, install the power steering pressure
switch into the power steering gear until fully seated. Then tighten the power steering pressure switch to a maximum torque of 8 N·m (70 in. lbs.).
(2) Install vehicle wiring harness connector (Fig. 7)
onto power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with lock­ing tab on power steering pressure switch.
For part reference and part location on the vehicle being serviced, refer to the following figure numbers. These figures show the hose bracket locations, hose routings and fitting locations. Use these figure num­bers when referring to the removal or installation procedures for the power steering hoses listed below.

REMOVE

(1) Raise vehicle.
(2) Remove bolt attaching power steering hose routing bracket to front suspension crossmember (Fig. 8).
Fig. 8 Power Steering Hose Routing Bracket
Page 15
STEERINGGEAR POWER STEERINGPRESSURE SWITCHPOWER STEERING FLUIDRETURN HOSEPOWER STEERINGFLUID PRESSUREHOSE
POWER STEERING PRES-SURE HOSETUBE CLIPPOWER STEERINGRETURN HOSEROUTING CLIPGENERATORSHIELDPOWER STEERING FLUIDRESERVOIR BOLT HOSECLAMP
ALTERNATORSHIELD ROUTING CLIP
POWER STEER-ING PUMP POWER STEERING PRES-SURE HOSEPOWER STEER-ING PUMPBRACKET LOCATING PIN BANJO BOLT
POWER STEERING PRES-SURE HOSEPOWER STEERING FLUIDRESERVOIR BOLT
TUBE CLIP
PL STEERING 19 - 15
REMOVAL AND INSTALLATION (Continued)
(3) Disconnect power steering pressure hose (Fig.
9) at power steering gear. Drain power steering fluid from power steering pump and hose through open end of hose.
Fig. 11 Power Steering Hose Attachment To
Generator Shield
Fig. 9 Power Steering Pressure Hose At Steering
Gear
(4) Remove power steering pressure hose from
routing clip on generator shield (Fig. 10).
Fig. 10 Power Steering Pressure Hose Routing Clip
At Generator Shield
(5) Lower vehicle. (6) Remove bolt, attaching power steering pressure
hose routing clip, to generator shield (Fig. 11).
(7) Loosen and remove Banjo bolt, and power steering pressure hose from pressure fitting on power steering pump (Fig. 12).
(8) Power steering fluid pressure hose is removed from the vehicle from the top of the engine compart­ment.
(9) Discard all used O-rings located at ends of power steering pressure hose and Banjo bolt.
Fig. 12 Power Steering Hose Attachment To Power
Steering Pump

INSTALL

(1) Install power steering pressure hose in vehicle
from top of engine compartment.
(2) Using a lint free towel, wipe clean all open power steering hose ends, and the power steering pump and steering gear ports.
(3) Install new O-ring on end of power steering pressure hose banjo fitting (Fig. 13).
(4) Install a new O-ring (Fig. 14) on power steering pressure hose banjo fitting bolt.
(5) Lubricate both O-rings using fresh clean power steering fluid.
(6) Install banjo bolt into the power steering pres­sure hose banjo fitting (Fig. 14).
(7) Attach power steering pressure hose to outlet fitting on power steering pump (Fig. 12). Do not
tighten or torque pressure fitting Banjo bolt at this time.
Page 16
POWER STEERING PRESSUREHOSE BANJO FITTINGO-RING
BANJO BOLT
O-RING
BANJO FITTINGBOLT
POWER STEERING PRESSURE
HOSE BANJO FITTING
19 - 16 STEERING PL
REMOVAL AND INSTALLATION (Continued)
(11) Install the power steering pressure and return hose routing clip on hoses (Fig. 8). Install bolt attach­ing routing clip to front suspension crossmember. Torque routing clip to front suspension crossmember attaching bolt to 23 N·m (17 ft. lbs.)
(12) Torque power steering pressure hose to steer­ing gear tube nut to 34 N·m (25 ft. lbs.).
(13) Install power steering pressure hose in rout­ing clip on generator shield (Fig. 10).
(14) Lower Vehicle.
(15) Position locating pin on power steering pres­sure hose banjo fitting so it is against power steering pump mounting bracket (Fig. 12). While holding locating pin against power steering pump bracket, torque pump end Banjo bolt to 34 N·m (25 ft. lbs.).
(16) Securely tighten bolt attaching power steering pressure hose bracket to generator shield.
Fig. 13 O-ring Installed On Power Steering Hose
Banjo Fitting
Fig. 14 O-ring Installed On Banjo Fitting Bolt
(8) Correctly route power steering pressure hose avoiding tight bends or kinking of the hose. Install power steering pressure hose to generator shield routing clip attaching screw (Fig. 11) but do not
tighten at this time.
(9) Raise vehicle.
(17) Start the engine and let run for a few seconds.
Then turn the engine off.
(18) Add fluid if necessary. Repeat the above pro­cedure until the fluid level remains constant after running the engine.
(19) Raise front wheels of vehicle off the ground.
(20) Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off.
(21) Add power steering fluid if necessary.
(22) Lower the vehicle and turn the steering wheel slowly from lock to lock.
(23) Stop the engine. Check the fluid level and refill as required.
(24) If the fluid is extremely foamy, allow the vehi­cle to stand a few minutes and repeat the above pro­cedure.
(25) After hose is installed, check for leaks at all hose connections.

POWER STEERING FLUID RETURN HOSE

CAUTION: Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent entry of foreign material into the compo­nents.
CAUTION: Hoses must remain away from exhaust system, vehicle components and unfriendly sur­faces causing possible damage to power steering hoses.
(10) Route power steering pressure hose to pres­sure port on power steering gear. Install power steer­ing pressure hose, on steering gear and loosely install tube nut into steering gear (Fig. 9). Tighten
and torque tube nut after routing bracket is installed, correctly positioning hoses in vehicle.
WARNING: POWER STEERING OIL, ENGINE PARTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DIS­CONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST.

REMOVE

(1) Raise vehicle. (2) Remove hose clamp, attaching return hose to
steel tube at power steering gear (Fig. 15). Let power
Page 17
GENERATOR SHIELD ROUTINGCLIP POWER STEERING RETURNHOSEPOWER STEERING PRES-SURE HOSEFRONT SUSPENSIONCROSSMEMBERGENERATOR
POWER STEERING PRES-SURE HOSEPOWER STEERING GEARSTEEL TUBEPOWER STEERING RETURNHOSEHOSECLAMP
POWER STEERING FLUID RETURNHOSE
POWER STEERING PRES-SURE HOSETUBE CLIPPOWER STEERINGRETURN HOSEROUTING CLIPGENERATORSHIELDPOWER STEERING FLUIDRESERVOIR BOLT HOSECLAMP
POWER STEERING FLUID SUPPLYHOSE
POWER STEERING FLUID
RESERVOIR
PL STEERING 19 - 17
REMOVAL AND INSTALLATION (Continued)
steering fluid, drain from return hose and power steering fluid reservoir, until reservoir is empty.
Fig. 17 Tube Clip At Generator Shield
18). Then remove power steering return hose from
Fig. 15 Power Steering Return Hose At Steering
Gear
(3) Remove power steering return hose from rout­ing clip on generator shield (Fig. 16).
power steering fluid reservoir.
Fig. 16 Power Steering Hose Routing Clip At
Generator Shield
(4) Lower vehicle.
(5) Remove tube clip at generator shield (Fig. 17) attaching power steering fluid return hose to power steering fluid pressure hose.
CAUTION: Care must be used when removing power steering fluid return hose from power steer­ing fluid reservoir. If excessive force is used when trying to remove hose from nipple on power steer­ing fluid reservoir, nipple can break off of the res­ervoir.
(6) Remove hose clamp, attaching power steering return hose to power steering fluid reservoir (Fig.
Fig. 18 Power Steering Return Hose At Reservoir
(7) Remove the power steering return hose from the vehicle. The power steering return hose is removed from the top of the engine compartment.

INSTALL

(1) Install power steering return hose on vehicle. Power steering return hose is installed from the top of the vehicles engine compartment.
CAUTION: Care must be used when installing power steering fluid return hose on power steering fluid reservoir. If excessive force is used when try­ing to install hose on nipple of power steering fluid reservoir, nipple can be broken off the reservoir.
(2) Install power steering return hose on power steering fluid reservoir fitting. Install hose clamp on power steering return hose at power steering fluid reservoir (Fig. 18). Be sure hose clamp is
Page 18
POWER STEERING FLUID RETURNHOSE
POWER STEERING FLUIDSUPPLY HOSE POWER STEERINGPUMPHOSECLAMP
POWER STEERING FLUID SUPPLYHOSE
POWER STEERING FLUID
RESERVOIR
19 - 18 STEERING PL
REMOVAL AND INSTALLATION (Continued)
installed on return hose past upset bead on power steering fluid reservoir.
(3) Raise vehicle. (4) Clip power steering return hose and pressure
hose together (Fig. 17).
(5) Install power steering return hose on steel tube at power steering gear (Fig. 15). Install hose clamp on power steering return hose at power steering gear (Fig. 15). Be sure hose clamp is installed on
return hose past upset bead on steel tube at power gear.
(6) Install power steering return hose on routing clip at generator shield (Fig. 16).
(7) Lower vehicle.
(8) Start the engine and let run for a few seconds. Then turn the engine off.
(9) Add fluid if necessary. Repeat the above proce­dure until the fluid level remains constant after run­ning the engine.
(10) Raise front wheels of vehicle off the ground.
(11) Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off.
(12) Add power steering fluid if necessary.
(13) Lower the vehicle and turn the steering wheel slowly from lock to lock.
(14) Stop the engine. Check the fluid level and refill as required.
(15) If the fluid is extremely foamy, allow the vehi­cle to stand a few minutes and repeat the above pro­cedure.
(16) After hose is installed, check for leaks at all hose connections.
(Fig. 19). Then remove power steering fluid supply hose from power steering fluid reservoir.
Fig. 19 Power Steering Fluid Supply Hose At
Reservoir
(2) Remove hose clamp, attaching power steering
fluid supply hose to the power steering pump (Fig.
20). Then remove power steering fluid supply hose from power steering pump fitting.

POWER STEERING FLUID SUPPLY HOSE RESERVOIR TO POWER STEERING PUMP

WARNING: POWER STEERING OIL, ENGINE PARTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DIS­CONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST.

REMOVE

CAUTION: Care must be used when removing the power steering fluid supply hose from power steer­ing fluid reservoir. If excessive force is used when trying to remove hose from nipple on power steer­ing fluid reservoir, nipple can break off of the res­ervoir.
(1) Remove hose clamp, attaching power steering fluid supply hose to power steering fluid reservoir
Fig. 20 Power Steering Fluid Supply Hose At Power
Steering Pump
(3) Remove power steering fluid supply hose from
engine.

INSTALL

(1) Install power steering fluid supply hose back
on engine making sure it is correctly routed.
CAUTION: Care must be used when installing power steering fluid supply hose on power steering fluid reservoir. If excessive force is used when try­ing to install hose on nipple of power steering fluid reservoir, nipple can be broken off the reservoir.
Page 19
POWER STEER-ING PUMP POWER STEERING PRES-SURE HOSEPOWER STEER-ING PUMPBRACKET LOCATING PIN BANJO BOLT
POWER STEERING FLUIDSUPPLY HOSE POWER STEERINGPUMPHOSECLAMP
PL STEERING 19 - 19
REMOVAL AND INSTALLATION (Continued)
(2) Install power steering fluid supply hose on power steering fluid reservoir fitting. Install hose clamp on power steering fluid supply hose at power steering fluid reservoir (Fig. 19). Be sure hose
clamp is installed on return hose past upset bead on power steering fluid reservoir.
(3) Install power steering fluid supply hose on power steering pump fitting. Install hose clamp on power steering fluid supply hose at power steering pump fitting (Fig. 20). Be sure hose clamp is
installed on power steering fluid supply hose past upset bead on power steering pump fit­ting.
(4) Start the engine and let run for a few seconds. Then turn the engine off.
(5) Add fluid if necessary. Repeat the above proce­dure until the fluid level remains constant after run­ning the engine.
(6) Raise front wheels of vehicle off the ground.
(7) Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off.
(8) Add power steering fluid if necessary.
(9) Lower the vehicle and turn the steering wheel slowly from lock to lock.
(10) Stop the engine. Check the fluid level and refill as required.
(11) If the fluid is extremely foamy, allow the vehi­cle to stand a few minutes and repeat the above pro­cedure.
(12) After hose is installed, check for leaks at all hose connections.
Fig. 21 Power Steering Hose Attachment To Power
Steering Pump
(3) Discard all used O-rings on the power steering
pressure hose Banjo fitting and Banjo bolt.
(4) Remove hose clamp attaching power steering fluid supply hose to the power steering pump suction fitting (Fig. 22). Remove power steering fluid supply hose from power steering pump fitting.

POWER STEERING PUMP (ALL ENGINES)

WARNING: POWER STEERING OIL, ENGINE COM­PONENTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DIS­CONNECTED HOSES, OR ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
The power steering pump removal procedure and pump and bracket fastener locations are the same for both engine applications used for this vehicle. The front power steering pump bracket must be removed as an assembly with the power steering pump and removed from the pump after removing the pulley from the power steering pump.

REMOVE

(1) Remove battery cable from (-) negative post on battery.
(2) Remove Banjo Bolt and power steering fluid pressure hose from pressure fitting on power steering pump (Fig. 21).
Fig. 22 Power Steering Fluid Supply Hose At Power
Steering Pump
(5) Raise vehicle on jackstands or centered on a frame contact type hoist. See hoisting in the Lubrica­tion And Maintenance Section of this service manual for the required lifting procedure to be used for this vehicle.
NOTE: If the vehicle is equipped with a dual over­head cam engine, the bolt attaching the coolant tube to the intake manifold needs to be removed. Refer to following step for required procedure.
(6) Remove the bolt attaching the coolant tube (Fig. 23) to the bottom of the intake manifold. The
Page 20
INTAKE MANIFOLDLOWER RADIATOR HOSEAIR CONDITIONING COM-PRESSOR COOLANT TUBEFRONT MOTOR MOUNT BOLT
CASTBRACKETMOUNTINGBOLTSPOWER STEER-ING PUMP
BOLT
POWER STEERING PUMP AIR CONDITIONING HOSEPOWER STEERING PUMPMOUNTING BRACKET
FRONT ENGINEMOUNT
FRONT POWER STEERING PUMP
POWER STEERING PUMP
MOUNTING BRACKET
19 - 20 STEERING PL
REMOVAL AND INSTALLATION (Continued)
bolt requires removal to allow the coolant tube to be moved out of the way for access to the power steering pump mounting bolt. The cool­ant tube does not need to be removed or the cooling system drained.
Fig. 25 Power Steering Pump Front Mounting
Bracket Bolt
Fig. 23 Coolant Tube To Intake Manifold Attachment
(7) Remove the 2 power steering pump to cast
bracket mounting and adjustment bolts (Fig. 24).
Fig. 24 Power Steering Pump Mounting Bolts (Rear)
NOTE: The power steering pump front mounting bracket is slotted at the bolt attaching it to the front engine mount (Fig. 25). This bolt only needs to be loosened to remove mounting bracket from engine.
(8) Loosen bolt (Fig. 25) attaching the power steer­ing pump front mounting to the front engine mount only far enough to slide the bracket out from under the bolt.
(9) Remove power steering pump drive belt from power steering pump pulley.
(10) Remove power steering pump and front mounting bracket as an assembly from the engine (Fig. 26).
Fig. 26 Power Steering Pump And Bracket
(11) Transfer required parts from removed power
steering pump to replacement power steering pump.

INSTALL

(1) Install power steering pump and mounting bracket as an assembly (Fig. 26) back on the engine using reverse of removal procedure.
(2) Slide front power steering pump bracket between bracket mounting bolt and front engine mount (Fig. 25). Be sure washer on bolt is
between the head of the bolt and bracket and does not get trapped between bracket and engine mount.
(3) Install the 2 power steering pump to cast mounting bracket attaching bolts (Fig. 24). Do not
tighten bolts at this time.
(4) Install power steering pump drive belt on power steering pump pulley.
(5) Install a 1/2 in. breaker bar in the square hole in the front power steering pump mounting bracket (Fig. 27). Then rotate pump in to obtain the correct
Page 21
POWER STEERINGPUMP BRACKET BREAKERBAR SQUARE OPENING ADJUSTPOWER STEERING PUMPPOWER STEERING PUMPDRIVE BELT
BANJO BOLT
POWER STEERING PRESSUREHOSE BANJO FITTINGO-RING
O-RING
BANJO FITTINGBOLT
POWER STEERING PRESSURE
HOSE BANJO FITTING
PL STEERING 19 - 21
REMOVAL AND INSTALLATION (Continued)
drive belt tension. See Accessory Drive Belts in Group 7 Cooling System of this service manual for the correct drive belt tension specification. When cor­rect drive belt tension is obtained torque the 2 bolts at the power steering pump cast mounting bracket (Fig. 24) to 54 N·m (40 ft. lbs.). Then torque the front power steering pump mounting bracket bolt (Fig. 25) to 54 N·m (40 ft. lbs.).
Fig. 27 Setting Power Steering Pump Drive Belt
Tension
(6) Install power steering supply hose on power steering pump suction fitting (Fig. 22). Install hose clamp on hose, being sure hose clamp is installed on hose past upset bead on power steering pump tube.
(7) Using a lint free towel, wipe clean all open power steering hose ends, and power steering pump fittings.
(8) Install a new O-ring on the end of the power steering pressure hose banjo fitting (Fig. 28).
Fig. 28 O-Ring Installed On Power Steering Hose
Banjo Fitting
(9) Install a new O-ring (Fig. 29) on power steering
fluid pressure hose banjo fitting bolt.
Fig. 29 O-Ring Installed On Banjo Fitting Bolt
(10) Lubricate both O-rings using fresh clean
power steering fluid.
(11) Install banjo bolt into the power steering pres-
sure hose banjo fitting.
(12) Attach power steering pressure hose on outlet
fitting of the power steering pump (Fig. 21).
(13) Position locating pin on power steering pres­sure hose banjo fitting so it is against power steering pump mounting bracket (Fig. 21). While holding locating pin against power steering pump bracket, torque pump end Banjo bolt to 34 N·m (25 ft. lbs.).
CAUTION: Do not use automatic transmission fluid in power steering system. Only use MoparT, Power Steering Fluid, or equivalent.
(14) Fill power steering reservoir to correct fluid level.
(15) Connect negative cable back on negative post of battery.
(16) Start the engine and let run for a few seconds. Then turn the engine off.
(17) Add fluid if necessary. Repeat the above pro­cedure until the fluid level remains constant after running the engine.
(18) Raise front wheels of vehicle off the ground.
(19) Start engine, then slowly turn steering wheel right and left several times until lightly contacting the wheel stops. Then turn the engine off.
(20) Add power steering fluid if necessary.
(21) Lower the vehicle. Start engine again and turn the steering wheel slowly from lock to lock.
(22) Stop the engine. Check the fluid level and refill as required.
Page 22
COOLANT RECOVERY SYS-TEM TANK
OVERFLOW HOSE FROMTHERMOSTAT HOUSING
HOSE CLAMP
POWER STEERING FLUID
POWER STEERING PRES-SURE HOSEPOWER STEERING GEARSTEEL TUBEPOWER STEERING RETURNHOSEHOSECLAMP
RIGHT FRONT STRUT
RESERVOIR
TOWER
COWLPANEL MOUNTINGSCREW
POWER STEERING FLUID RETURNHOSE
CRS
TANK
POWER STEERINGFLUID RESERVOIRMOUNTING NUT ANDSTUD
POWER STEERING FLUID SUPPLYHOSE
AIR CLEANER
POWER STEERING FLUID
ASSEMBLY
RESERVOIR
19 - 22 STEERING PL
REMOVAL AND INSTALLATION (Continued)
(23) If the fluid is extremely foamy, allow the vehi­cle to stand a few minutes and repeat the above pro­cedure.
(24) After power steering pump is installed, check for leaks at all hose connections and power steering pump fittings.

POWER STEERING FLUID RESERVOIR

REMOVE

(1) Raise vehicle on jack stands or on a frame con­tact type hoist. See Hoisting in the Lubrication And Maintenance Section of this service manual for the required lifting procedure to be used for this vehicle.
(2) Remove hose clamp, attaching return hose to steel tube at power steering gear (Fig. 30). Let power steering fluid drain from return hose and power steering fluid reservoir, until reservoir is empty.
NOTE: Removal of the CRS tank improves access to the power steering fluid reservoir attaching bolts.
(5) Remove the nut and screw attaching the CRS tank to the dash panel (Fig. 32). Remove the CRS tank from the dash panel and lower it down on top of the steering gear toward the center of the vehicle.
Fig. 32 CRS Tank Mounting Bolt And Screw
CAUTION: Care must be used when removing and installing power steering fluid hoses on the power steering fluid reservoir. If excessive force is used when trying to remove or install hoses on nipples of power steering fluid reservoir, nipples can be broken off the reservoir.
Fig. 30 Power Steering Return Hose At Steering
Gear
(3) Lower vehicle. (4) Remove the coolant overflow hose from the
coolant recovery system (CRS) tank (Fig. 31).
(6) Remove the power steering fluid return and supply hose from the power steering fluid reservoir (Fig. 33).
Fig. 33 Power Steering Fluid Hoses At Reservoir
(7) If vehicle is equipped with the single overhead cam engine, remove the 3 bolts (Fig. 34)
attaching the power steering fluid reservoir to the cylinder head.
Fig. 31 Overflow Hose Connection At CRS Tank
Page 23
POWER STEERING FLUIDRESERVOIR RETURN HOSESUPPLY HOSEPOWER STEERING FLUID RESER-VOIR MOUNTING BOLTSCYLINDERHEAD
POWER STEERING FLUIDRESERVOIR RETURN HOSE
POWER STEERING FLUID RESER-VOIR MOUNTING NUTSCYLINDER HEAD
SUPPLY HOSE
PL STEERING 19 - 23
REMOVAL AND INSTALLATION (Continued)
(4) Install the coolant overflow hose from the cool­ant recovery system (CRS) tank (Fig. 31)
(5) Raise vehicle.
(6) Install power steering return hose, on the steel tube at the power steering gear (Fig. 30). Be sure
hose clamp is installed on hose past upset bead on power steering gear steel tube.
(7) Fill power steering pump fluid reservoir to the proper level.
(8) Start the engine and let run for a few seconds. Then turn the engine off.
(9) Add fluid if necessary. Repeat the above proce­dure until the fluid level remains constant after run­ning the engine.
(10) Raise front wheels of vehicle off the ground.
(11) Start the engine. Slowly turn the steering
Fig. 34 Power Steering Fluid Reservoir Hoses And
Mounting
(8) If vehicle is equipped with the dual over-
head cam engine, remove the 2 nuts (Fig. 35)
attaching the power steering fluid reservoir to the cylinder head.
wheel right and left, lightly contacting the wheel stops. Then turn the engine off.
(12) Add power steering fluid if necessary.
(13) Lower the vehicle and turn the steering wheel slowly from lock to lock.
(14) Stop the engine. Check the fluid level and refill as required.
(15) If the fluid is extremely foamy, allow the vehi­cle to stand a few minutes and repeat the above pro­cedure.
Fig. 35 Power Steering Fluid Reservoir Mounting
(9) Remove power steering fluid reservoir from
vehicle.

INSTALL

(1) Install power steering fluid reservoir on cylin­der head. Install and securely tighten the power steering fluid reservoir to cylinder head attaching bolts (Fig. 34) or. (Fig. 35)
(2) Install the power steering fluid return and sup­ply hose, on the power steering fluid reservoir fit­tings (Fig. 33). Be sure both hose clamps are
installed on hose past upset bead on power steering reservoir fittings.
(3) Install engine coolant recovery system tank on dash panel of vehicle. Install and securely tighten attaching bolts (Fig. 32).

DISASSEMBLY AND ASSEMBLY

POWER STEERING PUMP DRIVE PULLEY

The power steering pump must be removed from the vehicle for removal of the power steering pump pulley. Refer to Power Steering Pump Removal in the Power Steering Pump Service Procedures section in this group of the service manual.

REMOVE

(1) Remove power steering pump from engine. Refer to Power Steering Pump Removal in the Power Steering Pump Service Procedures section in this group of the service manual for required procedure.
CAUTION: Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. This will damage the pulley and the power steering pump.
(2) Mount power steering pump in a vise using the power steering pump mounting bracket (Fig. 36). Install Puller, Special Tool C-4333 or C- 4068 on power steering pump pulley (Fig. 36). Remove the power steering pump pulley from the power steering pump shaft.
(3) Replace power steering pump pulley if bent, cracked, or loose.
Page 24
POWERSTEERINGPUMP POWER STEERING PUMP PULLEYSPECIAL TOOL C-4333 ORC-4068POWER STEERING PUMPMOUNTING BRACKET
POWER STEER-ING PUMP POWER STEER-ING PUMP PUL-LEYWRENCHWRENCHSPECIAL TOOLC-4063POWER STEERINGPUMP BRACKET
POWER STEERINGPUMP PULLEYHUB OF POWER STEERING PUMP PUL-LEY MUST BE FLUSH WITH PUMPSHAFT AS SHOWN TO CORRECTLYPOSITION PULLEYPOWER STEERING PUMPSHAFT
19 - 24 STEERING PL
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 36 Pulley Removal From Power Steering Pump
Shaft

INSTALL

CAUTION: Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. This will damage the pulley and the power steering pump.
(1) Mount power steering pump in a vise using the power steering pump mounting bracket (Fig. 37). Then place power steering pump pulley squarely on end of power steering pump shaft. Mount Installer, Special Tool C-4063 in internal threads of the power steering pump shaft and against power steering pump pulley (Fig. 37).
Fig. 37 Pulley Installation On Power Steering Pump
Shaft
(2) Ensuring that special tool and pulley remain aligned with pump shaft, force pulley onto power steering pump shaft until flush with the end of the shaft (Fig. 38). When pulley is flush with shaft
tool will no longer be able to be turned.
Fig. 38 Correctly Installed Power Steering Pump
Pulley
(3) Remove Installer, Special Tool C-4063 from
power steering pump.
(4) Install power steering pump and mounting bracket back on engine. Refer to Power Steering Pump Installation in the Power Steering Pump Ser­vice Procedures section in this group of the service manual for required procedure.

POWER STEERING PUMP MOUNTING BRACKET

DISASSEMBLE

(1) Remove power steering pump from engine. Refer to Power Steering Pump Removal And Instal­lation in the Power Steering Pump section in this group of the service manual for required procedure.
CAUTION: Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. This will damage the pulley and the power steering pump.
(2) Mount the power steering pump in a vise using the power steering pump mounting bracket (Fig. 39). Mount Puller, Special Tool C-4333 or C- 4068 on power steering pump pulley (Fig. 39). Remove the power steering pump pulley from the power steering pump shaft.
(3) Remove the 3 bolts attaching the power steer­ing pump to the mounting bracket (Fig. 40).
(4) Remove power steering pump from mounting bracket.

ASSEMBLE

(1) Install power steering pump on mounting bracket. Install the 3 power steering pump mounting bolts (Fig. 40). Torque the 3 mounting bolts to 54 N·m (40 ft. lbs.).
Page 25
POWERSTEERINGPUMP POWER STEERING PUMP PULLEYSPECIAL TOOL C-4333 ORC-4068POWER STEERING PUMPMOUNTING BRACKET
POWER STEERING PUMPMOUNTING BRACKET POWER STEER-ING PUMPMOUNTINGBOLTS
POWER STEER-ING PUMP POWER STEER-ING PUMP PUL-LEYWRENCHWRENCHSPECIAL TOOLC-4063POWER STEERINGPUMP BRACKET
POWER STEERINGPUMP PULLEYHUB OF POWER STEERING PUMP PUL-LEY MUST BE FLUSH WITH PUMPSHAFT AS SHOWN TO CORRECTLYPOSITION PULLEYPOWER STEERING PUMPSHAFT
PL STEERING 19 - 25
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 39 Pulley Removal From Power Steering Pump
Shaft
Fig. 40 Power Steering Pump Mounting Bolts
CAUTION: Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. This will damage the pulley and the power steering pump.
Fig. 41 Installing Pulley On Power Steering Pump
Shaft
Fig. 42 Correctly Installed Power Steering Pump
Pulley
vice Procedures section in this group of the service manual for required procedure.
(2) Place power steering pump pulley squarely on end of power steering pump shaft. Mount Installer, Special Tool C-4063 in internal threads of the power steering pump shaft and against power steering pump pulley (Fig. 41).
(3) Ensuring that special tool and pulley remain aligned with pump shaft, force pulley onto power steering pump shaft until flush with the end of the shaft (Fig. 42). When pulley is flush with shaft
tool will no longer be able to be turned.
(4) Remove Installer, Special Tool C-4063 from power steering pump.
(5) Install power steering pump and bracket assembly back on engine. Refer to Power Steering Pump Installation in the Power Steering Pump Ser-

SPECIFICATIONS

POWER STEERING PUMP FLOW SPECIFICATIONS

Power Steering Pump Flow:
At 1500 RPM And Minimum
Pressure ................4.9to5.3Liters/Min
(1.3 to 1.9 GPM)
Control Valve Pressure
Relief ....................8240 to 8920 kPa
(1195 to 1293 psi)
Page 26
19 - 26 STEERING PL
SPECIFICATIONS (Continued)
POWER STEERING PUMP FASTENER TORQUE SPECIFICATIONS
DESCRIPTION TORQUE Power Steering Hose:
Tube Nuts Pressure And
Return ...........................31N·m
(275 in. lbs.)
Bracket To Front Crossmember
Attaching Bolt .....................23N·m
(17 ft. lbs.).
Power Steering Pump:
Pressure Hose Banjo Bolt .....34N·m(25ft.lbs.).
Discharge Fitting ............75N·m(55ft.lbs.)
To Bracket Mounting Bolts ....54N·m(40. ft. lbs.)
Brackets To Engine Mounting
Bolts .............................54N·m
(40 ft. lbs.)

SPECIAL TOOLS

POWER STEERING PUMP
Installer C-4063B
Puller C-4333
P/S System Analyzer 6815
Page 27
TIE RODEND INNER TIE RODSTEERING GEAR BOOTSTEERING GEAR MOUNT-ING BRACKETPOWER STEERING GEARSTEERING GEAR FLUIDLINES STEERING GEAR COUPLERSTEERING GEAR BOOTINNER TIE RODTIE ROD ENDJAM NUTLOWER CONTROL ARMPOWER STEERING FLUIDHOSESFRONT SUSPENSIONCROSSMEMBERPOWER STEERING FLUIDRETURN HOSETO FLUID RESERVOIRTO POWER STEERINGPUMPPOWER STEERING FLUIDPRESSURE HOSE
PL STEERING 19 - 27

STEERING GEAR

INDEX
page page

DESCRIPTION AND OPERATION

STEERING GEAR ...................... 27
DIAGNOSIS AND TESTING
POWER STEERING SYSTEM TEST
REMOVAL AND INSTALLATION
MANUAL AND POWER STEERING GEAR .... 29
DESCRIPTION AND OPERATION
STEERING GEAR
The power steering system consists of these four major components. Power Steering Gear (Fig. 1), Power Steering Pump, Pressure Hose, and Return Line. Turning of the steering wheel is converted into linear travel through the meshing of the helical pin­ion teeth with the rack teeth. Power assist steering is provided by an open center, rotary type control valve which directs oil from the pump to either side of the integral rack piston.
DISASSEMBLY AND ASSEMBLY
OUTER TIE ROD END ................... 33
SPECIFICATIONS
STEERING GEAR FASTENER TORQUE
SPECIAL TOOLS
POWER STEERING GEAR ................ 34
Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle. This movement directs oil behind the integral rack piston, which, in turn, builds up hydraulic pressure and assists in the turning effort.
The drive tangs on the pinion of the power steering pump mate loosely with a stub shaft. This is to per­mit manual steering control to be maintained if the drive belt on the power steering pump should break. However, under these conditions, steering effort will be increased.
Fig. 1 Power Steering Gear Assembly
Page 28
SPECIAL TOOL6815 ADAPTER FIT-TINGS
PRESSURE HOSETO POWERSTEERING GEAR SPECIALTOOL 6815POWER STEER-ING PUMPTO POWERSTEERINGPUMP
19 - 28 STEERING PL
DESCRIPTION AND OPERATION (Continued)
NOTE: The power steering gear (Fig. 1) should NOT be serviced or adjusted. If a malfunction or oil leak occurs with the steering gear, the complete steering gear needs to be replaced.

DIAGNOSIS AND TESTING

POWER STEERING SYSTEM TEST PROCEDURE

The following procedure can be used to test the operation of the power steering system on the vehi­cle. This test will provide the flow rate of the power steering pump along with the maximum relief pres­sure. 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 pressure and flow test is performed using Pressure/Flow Tester, Special Tool 6815 (Fig. 2).
Fig. 3 Power Steering Pump Flow/Pressure Tester
Connected To Power Steering Pump
and repair as necessary. The initial pressure reading should be in the range of 345-552 kPa (50-80 psi). The flow meter should read between 1.3 and 1.4 GPM
Fig. 2 Power Steering Pump Flow/Pressure Tester

POWER STEERING PUMP FLOW AND PRESSURE TEST PROCEDURE

(1) Check power steering pump drive belt tension and adjust as necessary.
(2) Disconnect power steering fluid pressure hose, at power steering pump. Use a container for dripping fluid.
(3) Connect Pressure Gauge, Special Tool from kit 6815 (Fig. 3) to both hoses using adapter fittings. Connect spare pressure hose, to power steering pump pressure hose banjo fitting.
(4) Completely open valve on Special Tool 6815 (Fig. 3).
(5) Start engine and let idle long enough to circu­late power steering fluid through flow/pressure test and get air out of fluid. Then shut off engine.
(6) Check power steering fluid level, and add fluid as necessary. Start engine again and let idle.
(7) Pressure gauge should read below 862 kPa (125 psi), if above, inspect the hoses for restrictions
CAUTION: The following test procedure involves testing power steering pump maximum pressure output and flow control valve operation. Do not leave valve closed for more than 5 seconds as the pump could be damaged.
(8) Close valve fully three times and record high-
est pressure indicated each time. All three read-
ings must be above specifications and within 345 kPa (50 psi) of each other.
NOTE: Power steering pump maximum relief pres­sure is 8240 to 8920 kPa (1195 to 1293 psi.).
• If power steering pump pressures above specifi­cations but not within 345 kPa (50 psi) of each other, then replace power steering pump.
• If pressures within 345 kPa (50 psi) of each other but below specifications, then replace power steering pump.
CAUTION: Do not force the pump to operate against the stops for more than 5 seconds at a time because, pump damage will result.
(9) Open test valve. Turn steering wheel to the extreme left and right positions until against the stops, recording the highest indicated pressure at each position. Compare pressure gauge readings to power steering pump specifications. If highest output pressures are not the same against either stop, the steering gear is leaking internally and must be replaced.
Page 29
PINCH BOLTBRAKEPEDAL RETAINING PIN LOWER STEERINGCOLUMN COUPLERSTEERING COUPLERPINCH BOLT NUTSTEERING COLUMNSHAFT COUPLER
SAFETYCHAIN
TRANSAXLEBOBBLE DAMP-ENER FRONT SUSPENSIONCROSSMEMBER
STEERINGKNUCKLE TIE ROD END STUD NUT
BRAKINGDISC
TIE ROD
END
BRAKINGDISCSTEERINGKNUCKLE STUD SPECIALTOOLMB-990635
TIE ROD END
PL STEERING 19 - 29

REMOVAL AND INSTALLATION

MANUAL AND POWER STEERING GEAR

The removal and replacement procedure for both the manual and power steering gears is the same. The only additional steps of the procedure for the power steering gear, is the removal and replacement of the power steering fluid lines at the steering gear.

REMOVE

(1) From interior of vehicle, disconnect the steer­ing gear coupler, from the steering column shaft cou­pler (Fig. 4).
Fig. 5 Engine/Transaxle Bobble Dampener
Fig. 4 Steering Column To Steering Gear Coupler
(2) Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in the Lubri­cation and Maintenance section of this manual, for the required lifting procedure to be used for this vehicle.
(3) Remove both front wheel and tire assemblies from the vehicle.
(4) Remove engine/transaxle bobble dampener, on vehicles so equipped, from front suspension cross­member (Fig. 5). Bobble strut does not need to be removed from transaxle assembly.
(5) Remove nuts attaching both outer tie rod ends to the steering knuckles (Fig. 6). Nuts are to be
removed from tie rod ends using the following procedure, hold tie rod end stud with an 11/32 socket, while loosening and removing nut with wrench.
(6) Remove both tie rod end studs, from the steer­ing knuckles, using Remover, Special Tool MB-990635 (Fig. 7).
Fig. 6 Removing Tie Rod End Attaching Nut
Fig. 7 Tie Rod End Removal From Steering Knuckle
Page 30
STEERINGGEAR POWER STEERINGPRESSURE SWITCHPOWER STEERING FLUIDRETURN HOSEPOWER STEERINGFLUID PRESSUREHOSE
19 - 30 STEERING PL
VEHICLE WIR-ING HARNESS STEERING GEARVEHICLE WIRING HAR-NESS CONNECTOR FRONT SUSPENSIONCROSSMEMBER POWER STEERINGFLUID PRESSURESWITCH
REMOVAL AND INSTALLATION (Continued)
(7) If equipped, remove vehicle wiring harness con­nector from the power steering fluid pressure switch (Fig. 8).
POWER STEERING PRES-SURE HOSE ROUTING BRACKETPOWER STEERING RETURNHOSE BOLT
Fig. 10 Power Steering Fluid Pressure And Return
Hoses
relation to the vehicle body. This process is carried
Fig. 8 Power Steering Fluid Pressure Switch
Electrical Connector
(8) If vehicle is equipped with power steering, remove power steering pressure and return hose routing bracket from front suspension crossmember (Fig. 9). The hose routing bracket does not have
to be removed from the power steering pres­sure and return hoses.
out when building the vehicle, by accurately locat­ing the front suspension crossmember, to master gage holes located in the underbody of the vehicle. With this method of designing and building a vehi­cle, it is no longer possible to adjust a vehicles front suspension alignment settings to the required specifications. Due to this, whenever the front sus­pension crossmember is removed from a vehicle, it MUST be replaced in the same location on the body of the vehicle it was removed from. Front suspen­sion Toe settings though are still adjustable by the outer tie rod ends.
Fig. 9 Power Steering Pressure And Return Hose
Routing Bracket
(9) If vehicle is equipped with power steering, remove power steering fluid, pressure and return hoses (Fig. 10) from the power steering gear assem­bly.
NOTE: This vehicle is designed and assembled using NET BUILD front suspension alignment set­tings. This means that front suspension alignment settings are determined as the vehicle is designed by the location of front suspension components in
CAUTION: Before removing front suspension crossmember from the vehicle, the location of the front suspension crossmember MUST be scribbed on body of vehicle per (Fig. 9). This must be done so crossmember can be relocated against body of vehicle in the same location when it is reinstalled. If location of front suspension crossmember to body of vehicle is not maintained when vehicle is assem­bled, NET BUILD front suspension alignment set­tings will not be obtained. This may lead to handling and or tire wear problems.
(10) Using an awl, scribe a line (Fig. 11) marking the location of where front suspension crossmember is mounted against the body of the vehicle.
(11) Position a transmission jack under the center of the front suspension crossmember (Fig. 12). Trans­mission jack is used to lower, support and raise front suspension crossmember when removing steering gear assembly.
(12) Loosen and fully remove the front 2 bolts (Fig.
13) attaching front suspension crossmember to frame rails of vehicle. Then loosen the 2 rear bolts (Fig. 13)
Page 31
SCRIBBED LINE FOR LOCATION OFFRONT SUSPENSION CROSSMEMBERLOWER CON-TROL ARMLOWER CONTROL ARMBUSHING MOUNTINGBOLT FRONT SUSPENSIONCROSSMEMBERAWL
STEERINGGEARSWAYBARFRONT SUSPENSIONCROSSMEMBER TRANSMISSION JACK
PL STEERING 19 - 31
REMOVAL AND INSTALLATION (Continued)
Fig. 11 Marking Front Suspension Crossmember
Location
FRONT SUSPENSION
CROSSMEMBER
STEERING GEAR COUPLER
STEERING GEAR MOUNTINGBOLTS (4)
STEERING GEARSWAY BAR TRANSMISSIONJACK
STEERING
CROSSMEMBERMOUNTING BOLTCROSSMEMBERMOUNTING BOLTLOWER CONTROLARM TRANSMISSIONJACK FRONT SUSPENSIONCROSSMEMBER
GEAR
LOWER CONTROL ARM
Fig. 13 Front Suspension Crossmember Mounting
Bolts
Fig. 12 Supporting Front Suspension Crossmember
attaching front suspension crossmember and lower control arm to body of vehicle. Lower front suspen-
sion crossmember while loosening rear bolts, but do not remove rear bolts from crossmem­ber.
(13) Using transmission jack, lower front suspen­sion crossmember enough to allow steering gear to be removed from crossmember (Fig. 14). When lower-
ing front suspension crossmember, do not let crossmember hang from lower control arms weight of crossmember should be supported by transmission jack.
(14) Loosen and remove the 4 bolts (Fig. 15), attaching steering assembly to front suspension crossmember. Then remove the steering gear assem­bly from the front suspension crossmember.
(15) Transfer required parts from removed steering gear assembly to the replacement steering gear, if a new steering gear is being installed.
Fig. 14 Crossmember Lowered For Removal Of
Steering Gear
Fig. 15 Steering Gear Assembly Mounting Bolts
Page 32
19 - 32 STEERING PL
TIE RODEND STEERINGKNUCKLELOWER CONTROLARM11/32SOCKETTORQUEWRENCH CROWFOOT
REMOVAL AND INSTALLATION (Continued)
FRONT SUSPEN-SION CROSS-MEMBERPOSITIONINGMARK LOWER CONTROLARM
LOWER CONTROL ARM/ CROSSMEMBER MOUNTING

INSTALL

BOLT
(1) Install steering gear assembly on front suspen­sion crossmember. Install the 4 steering gear assem­bly to front crossmember mounting bolts (Fig. 15). Torque the 4 steering gear mounting bolts to 68 N·m (50 ft. lbs.).
(2) Using the transmission jack, raise front sus­pension crossmember and steering gear against body and frame rails of vehicle. Start the 2 rear bolts into tapping plates, attaching front suspension crossmem­ber to body of vehicle (Fig. 13). Then install the 2 front bolts, attaching front suspension crossmember to frame rails of vehicle (Fig. 13). Tighten the 4 mounting bolts, until front suspension crossmember is against body of vehicle at the 4 mounting points. Then torque the 4 mounting bolts to 2 N·m (20 in. lbs.) to hold front suspension crossmember in posi­tion.
CAUTION: When front suspension crossmember is installed back in vehicle, crossmember MUST be aligned with positioning marks previously scribbed into body of vehicle (Fig. 16). This MUST be done to maintain NET BUILD front suspension alignment settings.
FRONT SUSPENSIONCROSSMEMBER
assembly (Fig. 10). Torque power steering fluid pres­sure and return lines to steering gear tube nuts (Fig.
10) to 31 N·m (275 in. lbs.). (5) If vehicle is equipped with power steering,
install power steering pressure and return hose rout­ing bracket and attaching screw on front suspension crossmember (Fig. 9). Torque hose routing bracket to crossmember attaching bolt (Fig. 9) to 23 N·m (17 ft, lbs.).
(6) If the vehicle is equipped with power steering,
install vehicle wiring harness connector onto power steering fluid pressure switch on steering gear assembly (Fig. 8). Be sure locking tab on wiring har­ness connector is securely latched to pressure switch.
(7) 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. 6). Then using a crowfoot and 11/32 socket (Fig. 17), torque tie rod end attach­ing nut to 55 N·m (40 ft. lbs.).
(3) Using a soft face hammer, tap front suspension crossmember into position, until it is aligned with the 2 previously scribbed positioning marks on body of vehicle (Fig. 16). When front suspension cross­member is correctly positioned, torque the 2 rear crossmember/lower control arm mounting bolts to 163 N·m (120 ft. lbs.). Then torque the 2 front cross­member to frame rail attaching bolts to 163 N·m (120 ft. lbs.) (Fig. 13).
Fig. 16 Crossmember Aligned With Positioning
Marks
(4) If vehicle is equipped with power steering, install power steering fluid pressure and return hoses into correct fluid ports on power steering gear
Fig. 17 Torquing Tie Rod End Attaching Nut
(8) Install engine/transaxle bobble strut (Fig. 5) back on front suspension crossmember bracket. Install and securely tighten the dampener to cross­member attaching bolt.
(9) Install the wheel and tire assemblies back on vehicle. Tighten the wheel nuts to 135 N·m (100 ft. lbs.) torque.
(10) Lower vehicle.
(11) From interior of vehicle, reconnect the steer­ing gear coupler with the steering column shaft cou­pler. Install steering gear coupler retaining pinch bolt and torque to 28 N·m (250 in. lbs.). Be sure to
install the upper to lower steering coupler retaining bolt, retention pin (Fig. 4).
CAUTION: Do not use automatic transmission fluid.
Page 33
INNER TIE ROD OUTER TIE ROD ENDOUTER TIE ROD JAM NUTINNER TIE ROD SERRA-TION STEERINGKNUCKLE
PL STEERING 19 - 33
INNER TIE ROD OUTER TIE ROD ENDOUTER TIE ROD JAM NUTINNER TIE ROD SERRA-TION STEERINGKNUCKLE
BRAKINGDISC
NUT TIE ROD END STUDSTEERINGKNUCKLE
TIE ROD END
REMOVAL AND INSTALLATION (Continued)
(12) Fill power steering pump fluid reservoir to the
(Full-Cold) proper level.
(13) Start the engine and let run for a few seconds.
Then turn the engine off.
(14) Add fluid if necessary. (15) Raise front wheels of vehicle off the ground.
(16) Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in sys­tem. Stop engine, check fluid level, and inspect sys­tem for leaks. Fill pump reservoir to correct
level with Mopart, Power Steering Fluid, or equivalent. See Checking Fluid Level.
(17) Lower front wheels of vehicle back on the ground.
CAUTION: During this procedure do not allow the steering gear inner tie rod boots to become twisted. (See Wheel Alignment in the suspension section of this service manual).
(18) Adjust the front Toe setting on the vehicle. Refer to the Toe Setting Procedure in Front Suspen­sion Service Procedures in this group of the service manual. Refer to the Specifications Section at the end of this group for the desired front Toe specifica­tion.
(19) Tighten tie rod jam nut (Fig. 18) to 61 N·m (45 ft.lbs.) torque.
(2) Remove the nut attaching the outer tie rod end
to steering knuckle (Fig. 20). Nut is to be removed
from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with wrench.
Fig. 19 Outer Tie Rod
Fig. 18 Outer Tie Rod End Jam Nut
(20) Adjust steering gear to tie rod boots at tie rods.

DISASSEMBLY AND ASSEMBLY

OUTER TIE ROD END

DISASSEMBLE

(1) Loosen the inner tie rod to outer tie rod jam nut (Fig. 19).
Fig. 20 Removing /Installing Tie Rod End Attaching
Nut
(3) Remove the tie rod end stud from steering knuckle arm, using Remover, Special Tool MB-990635 (Fig. 21).
(4) Remove the outer tie rod end from the inner tie rod by un-threading it from the inner tie rod.

ASSEMBLE

(1) Install outer tie rod onto inner tie rod. Make sure jam nut is on inner tie rod (Fig. 19).
(2) Do not tighten jam nut.
(3) Install the 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 steer-
Page 34
SAFETYCHAIN
TIE RODEND STEERINGKNUCKLELOWER CONTROLARM11/32SOCKETCROWFOOT TORQUEWRENCH
TIE ROD
END
BRAKINGDISCSPECIAL TOOLMB-990635 STUD STEERINGKNUCKLE
19 - 34 STEERING PL
DISASSEMBLY AND ASSEMBLY (Continued)

SPECIFICATIONS

STEERING GEAR FASTENER TORQUE SPECIFICATIONS

DESCRIPTION TORQUE FRONT SUSPENSION CROSSMEMBER:
To Body Mounting Bolts .....163N·m(120 ft. lbs.)
STEERING GEAR:
To Crossmember Mounting Bolts . 68 N·m (50 ft. lbs.)
OUTER TIE ROD:
To Steering Knuckle Nut ......55N·m(40ft.lbs.)
To Inner Tie Rod Jam Nut .....61N·m(45ft.lbs.)
POWER STEERING HOSE:
Tube Nuts ................31N·m(275 in. lbs.)
Fig. 21 Tie Rod End Removal From Steering
Knuckle
ing knuckle attaching nut (Fig. 20). Then using a crowfoot and 11/32 socket (Fig. 22), torque the tie rod end attaching nut to 61 N·m (45 ft. lbs.).
Routing Bracket At
Crossmember .............23N·m(17ft.lbs.)

SPECIAL TOOLS

POWER STEERING GEAR

Fig. 22 Torquing Tie Rod End Attaching Nut
CAUTION: During this procedure do not allow the steering gear boot to become twisted. (See Wheel Alignment in the suspension section of this service manual).
(4) Adjust the front Toe setting on the vehicle. Refer to the Toe Setting Procedure in Front Suspen­sion Service Procedures in this group of the service manual. Refer to the Specifications Section at the end of this group for the desired front Toe specifica­tion.
(5) Torque the tie rod jam nut (Fig. 19) to a torque of 55 N·m (40 ft. lbs.) torque.
(6) Adjust the steering gear to inner tie rod boots at inner tie rod if they became twisted during Toe adjustment.
Remover Tie Rod End MB–990635
P/S System Analyzer 6815
Installer Boot Clamp C-4975A
Page 35
PL STEERING 19 - 35
STEERING COLUMN
INDEX
page page

DESCRIPTION AND OPERATION

STEERING COLUMN ASSEMBLY ........... 35
STEERING GEAR TO STEERING COLUMN
DIAGNOSIS AND TESTING
STEERING COLUMN TO STEERING GEAR
STEERING COLUMN .................... 37
DESCRIPTION AND OPERATION

STEERING COLUMN ASSEMBLY

Both the standard non-tilt and tilt steering col­umns (Fig. 1) have been designed to be serviced only as complete assemblies, if a component of the steer­ing column is defective. The only replaceable compo­nents of the steering column assembly, are the key
REMOVAL AND INSTALLATION
STEERING COLUMN SERVICE PROCEDURE
STEERING COLUMN .................... 38
SPECIFICATIONS
STEERING COLUMN FASTENER TORQUE
cylinder, ignition switch, multi- function switch, clock spring, trim shrouds and steering wheel. These replaceable components of the steering column can be serviced without requiring removal of the steering column from the vehicle.
Page 36
19 - 36 STEERING PL
DESCRIPTION AND OPERATION (Continued)
Fig. 1 Non-Tilt And Tilt Steering Column Assemblies
Page 37
COUPLING FLEX JOINT(ATTACHMENT TO STEER-ING GEAR) FLOOR PAN SEAL TO COU-PLING SEALING SURFACETO STEERINGCOLUMNSTEERING COLUMN COU-PLING SEALING COLLARCOUPLING CONVO-LUTED TUBE
LOWER STEERING COLUMNCOUPLER UPPER STEERING COL-UMN SHAFT COUPLERSILENCER SEALBRAKEPEDAL
STEERING COUPLINGPINCH BOLT NUT STEERING COLUMNSHAFT COUPLINGSTEERING COL-UMN TO STEER-ING GEARCOUPLINGPINCH BOLT SAFETY PINBRAKEPEDALPINCHBOLT
PL STEERING 19 - 37
DESCRIPTION AND OPERATION (Continued)

STEERING GEAR TO STEERING COLUMN COUPLING

This vehicle uses a differently designed coupling for connecting the steering column to the steering gear (Fig. 2).
This coupling (Fig. 2) is different in its appearance and in the way it functions than the previous cou­pling used on this vehicle and couplings used on other Chrysler vehicles. This coupling functions by bending at the bellows section (Fig. 2) of the coupling on impact, where as the previous coupling separated at its detachable joint on an impact.
This coupling incorporates a hollow convoluted tube (Fig. 2) which allows the coupling to bend as required when a vehicle is involved in a collision. The previous coupling used on this vehicle incorporated 2 release washers which allowed the coupling to sepa­rate into 2 pieces, if necessary, when a vehicle was involved in a collision.
(2) If a vehicle is involved in an impact of the vehi­cles front suspension or under carriage, which results in any type of damage to the front suspension cross­member.
(3) Under any conditions which result in the steer­ing column assembly or steering column shaft receiv­ing a force great enough to move the steering column or shaft forward or rearward in a vehicle.

STEERING COUPLING INSPECTION PROCEDURE

(1) Remove the pinch bolt safety pin from the steering column shaft coupling pinch bolt (Fig. 3).
(2) Loosen the coupling pinch bolt retaining nut and remove pinch bolt (Fig. 3) from steering coupler.
(Pinch bolt nut is caged to coupler and is not removable.) Then separate the steering column
shaft coupling from the steering column to steering gear coupling.
Fig. 2 Steering Column Coupler

DIAGNOSIS AND TESTING

STEERING COLUMN

For diagnosis of conditions relating to the steering column, refer to the steering system diagnosis charts, in the diagnosis and testing section at the beginning of this group.

STEERING COLUMN TO STEERING GEAR COUPLING

STEERING COLUMN COUPLING INSPECTION

The steering column coupling MUST be inspected whenever a vehicle is involved in an impact or when­ever any of the following conditions exist.
(1) The steering column coupling must be inspected whenever a vehicle is involved in a colli­sion which deploys the air bag, regardless of the extent of damage done to the vehicle.
Fig. 3 Steering Column To Coupling Attachment
(3) Remove the silencer seal (Fig. 4) enclosing the
steering column coupling.
Fig. 4 Steering Column Coupling Seal
Page 38
CONVOLUTED SECTION OFCOUPLING SEALING COLLARSTEERING COLUMN COU-PLING
19 - 38 STEERING PL
DIAGNOSIS AND TESTING (Continued)
(4) Inspect steering column coupling in the follow­ing areas for signs of damage:
Inspect the sealing collar on the steering column
•
coupling (Fig. 5) to ensure the it is not cracked, broken, or otherwise damaged requiring coupling replacement.
• Inspect the convoluted section (Fig. 5) of the steering column coupling for the following conditions or any other visible signs of damage.
• Uneven spacing between the convolutes on the
coupling.
• Dings or dents in the convolutes of the cou-
pling or anywhere else on the coupling wall.
A bend in the convoluted section of the coupling.
•
Fig. 5 Steering Column Coupling Inspection
If any of the preceding conditions exist the steering
coupling MUST be replaced.
The steering gear must be removed from the vehi­cle to allow access for replacement of the steering coupling. Refer to Steering Gear Service Procedures in this group of the service manual for the required steering gear removal procedure.
(5) If steering coupling does not require replace­ment, install steering column coupling silencer seal (Fig. 4) back on vehicle.
(6) Ensure front wheels of vehicle are positioned straight-ahead and then align and attach steering column to steering coupling (Fig. 3). Install the cou­pling pinch bolt (Fig. 3). Tighten the pinch bolt nut to a torque of 28 N·m (250 in. lbs.). Be sure to
install upper to lower steering coupling pinch bolt safety pin (Fig. 3).

REMOVAL AND INSTALLATION

STEERING COLUMN SERVICE PROCEDURE WARNINGS

WARNING: BEFORE BEGINNING ANY SERVICE PRO­CEDURES THAT INVOLVES REMOVING THE AIR BAG. REMOVE AND ISOLATE THE NEGATIVE (-) BATTERY CABLE (GROUND) FROM THE VEHICLE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR BAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSI­BLE PERSONAL INJURY.
WARNING: THE AIR BAG SYSTEM IS A SENSITIVE, COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL THE AIR BAG SYSTEM COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIR BAG AND POSSIBLE PERSONAL INJURY. THE FASTENERS, SCREWS, AND BOLTS, ORIGI­NALLY USED FOR THE AIR BAG COMPONENTS, HAVE SPECIAL COATINGS AND ARE SPECIFI­CALLY DESIGNED FOR THE AIR BAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUB­STITUTES. ANYTIME A NEW FASTENER IS NEEDED, REPLACE WITH THE CORRECT FASTEN­ERS PROVIDED IN THE SERVICE PACKAGE OR FASTENERS LISTED IN THE PARTS BOOKS. BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIR BAG, REFER TO GROUP 8M, ELECTRICAL FOR PROPER AND SAFE SER­VICE PROCEDURES.
NOTE: Safety goggles should be worn at all times when working on steering columns.
CAUTION: Disconnect negative (ground) cable from the battery, before servicing any column com­ponent.
CAUTION: Do not attempt to remove the pivot pins to disassemble the tilting mechanism. Damage will occur.

STEERING COLUMN

REMOVE

(1) Disconnect the negative (ground) cable from
the battery and isolate cable.
(2) Before beginning removal of steering column assembly from vehicle, be sure front wheels of vehicle are in the straight ahead position.
(3) Remove the 4 screws attaching steering column cover, to lower instrument panel. Then remove the trim panel from the instrument panel (Fig. 6).
(4) Remove 3 screws (Fig. 7) attaching the steering column cover liner to the instrument panel. Remove the liner from the lower instrument panel.
(5) If vehicle is equipped with speed control, remove the speed control switches from the steering wheel (Fig. 8). If vehicle is not equipped with speed control, remove the trim covers from the sides of the steering wheel.
Page 39
HEAD LAMPSWITCH ATTACHINGSCREWSSTEERING COLUMN COVERLINERATTACHINGSCREW STEERINGCOLUMN
ATTACHINGSCREWFUSE ACCESSPANEL HEAD LAMPSWITCH STEERINGCOLUMNSTEERING COLUMNCOVER ATTACHINGSCREWS
STEERING WHEELSPEED CONTROLSWITCHESAIRBAGMOUNTING SCREWS
PL STEERING 19 - 39
REMOVAL AND INSTALLATION (Continued)
Fig. 6 Steering Column Cover
STEERINGWHEEL AIRBAG MOD-ULEAIRBAG MODULEATTACHING BOLTSPEED CONTROL SWITCH WIRINGCONNECTOR
WARNING: WHEN AN UNDEPLOYED AIR BAG ASSEMBLY IS TO BE REMOVED FROM THE STEER­ING WHEEL, DISCONNECT BATTERY GROUND CABLE AND ISOLATE. ALLOW SYSTEM CAPACITOR TO DIS­CHARGE FOR TWO MINUTES, THEN BEGIN AIR BAG REMOVAL.
(6) Remove the 2 fasteners, 1 on each side of steer­ing wheel, attaching the air bag module to the steer­ing wheel (Fig. 9).
Fig. 7 Steering Column Cover Liner
Fig. 9 Air Bag Module Mounting Bolts
WARNING: WHEN HANDLING AN UNDEPLOYED AIR BAG MODULE DURING SERVICING OF THE STEERING COLUMN THE FOLLOWING PRECAU­TIONS SHOULD BE OBSERVED. AT NO TIME SHOULD ANY SOURCE OF ELECTRICITY BE PER­MITTED NEAR THE INFLATOR ON THE BACK OF THE AIR BAG MODULE. WHEN CARRYING A LIVE MODULE, THE TRIM COVER SHOULD BE POINTED AWAY FROM THE BODY TO MINIMIZE INJURY IF MODULE ACCIDENTLY DEPLOYS. IF AIR BAG MOD­ULE IS PLACED ON A BENCH OR OTHER SUR­FACE, PLASTIC COVER SHOULD BE FACE UP TO MINIMIZE MOVEMENT IN CASE OF ACCIDENTAL DEPLOYMENT.
Fig. 8 Speed Control Switches
Page 40
19 - 40 STEERING PL
SPEED CONTROL SWITCHELECTRICAL CONNECTORAIRBAG MODULE ELECTRI-CAL CONNECTOR FROMCLOCK SPRINGAIRBAG MODULESTEERING WHEELSPEED CONTROL SWITCHELECTRICAL CONNECTOR
REMOVAL AND INSTALLATION (Continued)
(7) Remove air bag module from center of steering wheel. Then disconnect the clock spring electrical lead from the back of the air bag module (Fig. 10).
in the airbag module from the wiring lead coming from the clockspring (Fig. 11).
AIRBAG MODULEHORN SWITCH WIRINGLEADSTEERING WHEELCLOCKSPRING
STEERING WHEEL PULLERSTEERING WHEEL
Fig. 12 Steering Wheel Attaching Nut
(12) Install Puller, Snap-On CJ2001P or an equiv-
alent on the steering wheel (Fig. 13).
Fig. 10 Air Bag Module Electrical Connection
(8) Disconnect the wiring lead for the horn switch
Fig. 11 Clock Spring To Horn Switch Wiring
Connection
(9) Turn the lock cylinder to the off position and remove the key from the lock cylinder
(10) Turn the steering wheel to the left 1/2 a turn (180°) until the steering column lock is engaged (Fig.
12).
(11) Remove the steering wheel retaining nut, from the steering column shaft (Fig. 12).
CAUTION: When installing Puller, Special Tool C-3428-B on steering wheel be sure puller bolts are fully seated in threaded puller holes on steering wheel. If bolts are not fully seated in threaded holes, threads may be stripped out when puller is tightened to remove steering wheel.
Fig. 13 Steering Wheel Puller Installed
CAUTION: Do not bump or hammer on steering wheel or steering column shaft when removing steering wheel from steering column.
(13) Remove steering wheel assembly from steer­ing column shaft using Puller, Special Tool C-3428-B or equivalent.
(14) Remove key lock cylinder from steering col­umn. Key lock cylinder is removed from steering col­umn using the following procedure. Place the key lock cylinder in the Run position. Then through the hole in lower shroud, (Fig. 14) depress lock cylinder retaining tab and remove key lock cylinder.
(15) Remove the 3 screws attaching the upper and lower shroud to the steering column (Fig. 15). First remove lower shroud from steering column, then release tilt lever and tilt steering column to its low­est point. Then remove upper shroud from steering column.
Page 41
PL STEERING 19 - 41
REMOVAL AND INSTALLATION (Continued)
STEERINGCOLUMN LOWER STEERING COL-UMN SHROUD FASTEN-ERS
TILT
LOWER STEERING COL-
LEVER
UMN SHROUD
Fig. 14 Key Lock Cylinder Access Hole In Steering
Column Shrouds
STEERING COLUMN
JACKET
TILT LEVER STEERING
VEHICLE WIR-ING HARNESS
WIRING HARNESS
ROUTING CLIP
COLUMN ATTACHING
NUTS
TURN SIGNALSWITCH
MULTI-FUNCTIONSWITCHINSTRUMENT PANEL
STEERING COLUMNSUPPORT BRACKETUPPER STEERING COLUMNMOUNTING BATWINGBRACKET
Fig. 16 Upper To Lower Steering Column Coupler
Disassembly
Fig. 15 Upper And Lower Steering Column Shrouds
(16) Remove retaining pin in the upper to lower
steering column coupler pinch bolt (Fig. 16).
(17) Loosen the upper to lower steering coupler
pinch bolt retaining nut and remove pinch bolt (Fig.
16) from steering coupler. (Pinch bolt nut is caged to coupler and is not removable.) Then separate upper steering coupler from lower steering coupler shaft.
(18) Remove the 4 nuts attaching the lower mounting bracket of the steering column to the boby mounting bracket for the steeing column.
(19) Remove the 2 steering column assembly upper bat wing bracket to support bracket nuts (Fig. 17).
(20) Lower steering column assembly in the steer­ing column access opening of the lower instrument panel.
(21) Remove routing clip (Fig. 18) holding wiring harness to jacket of steering column. Then remove wiring harness connectors from the multi- function switch and the windshield wiper switch (Fig. 18).
Fig. 17 Steering Column Upper Support Bracket
Attaching Nuts
Fig. 18 Steering Column Wiring Connections
Page 42
TILT LEVER
IGNITION SWITCH CLOCKSPRINGVEHICLE WIRINGHARNESS
19 - 42 STEERING PL
REMOVAL AND INSTALLATION (Continued)
(22) Remove the vehicle wiring harness connec­tors from the ignition switch and clock spring (Fig.
19).
Fig. 19 Steering Column Wiring Connections
(23) Remove steering column assembly from vehi­cle through the drivers door of the passenger com­partment. Use care to avoid damaging the paint or interior trim.

INSTALL

(1) Install steering column into steering column access opening in lower instrument panel.
(2) Install the vehicle wiring harness connectors, into the ignition switch and clock spring assembly (Fig. 19).
(3) Install vehicle wiring harness connectors into multi-function switch and turn signal switch (Fig. 18) on steering column assembly. Install routing clip (Fig. 18) holding wiring harness to jacket of steering column.
(4) Install the studs in the steering column sup­port bracket, into the slots in the plastic capsules of the upper mounting bracket of the steering column (Fig. 17). Partially install the 2 upper steering col­umn assembly mounting bracket to support bracket attaching nuts (Fig. 17). Do not tighten the 2
mounting nuts at this time.
(5) Align the bolt holes in the steering column lower mounting bracket with the threaded holes in the boby mounting bracket for the steeing column. Install and loosely tighten the steering column lower mounting bracket bolts.
(6) Install the upper and lower steering column shrouds onto the lock housing of the steering column assembly. Install and securely tighten the 3 upper to lower steering column shroud to lock housing attach­ing screws (Fig. 15).
(7) Be sure both breakaway capsules are still fully seated in the slots of the upper steering column mounting bracket. Equally tighten both steering col­umn mounting nuts, until upper steering column mounting bracket is seated against support bracket. Then tighten the 2 steering column upper mounting bracket nuts to a torque of 17 N·m (150 in. lbs.).
(8) Tighten the steering column lower mounting bracket nuts (2) to a torque of 17 N·m (150 in. lbs.).
(9) Assemble the steering column flex coupler to the intermediate steering coupler (Fig. 16). Install the steering coupler pinch bolt. Torque the pinch bolt nut to 28 N·m (250 in. lbs.). Be sure to install
upper to lower steering coupler pinch bolt retaining pin (Fig. 16).
(10) Install the lower instrument panel steering column cover liner onto lower instrument panel. Install and securely tighten the 3 liner to instrument panel attaching screws (Fig. 7).
(11) Install lower instrument panel steering col­umn cover (Fig. 6) on lower instrument panel. Install and securely tighten the 4 screws (Fig. 6) attaching steering column cover, to lower instrument panel.
CAUTION: Clock spring centering procedure MUST be performed prior to installing steering wheel assembly. If clock spring is not centered it may be overextended, causing clock spring assembly to become inoperative.
(12) Center the clock spring using the following procedure.
• Depress the 2 plastic locking pins to disengage
clockspring locking mechanism.
• Keeping locking mechanism disengaged, rotate the clockspring rotor in the CLOCKWISE DIREC­TION to the end of the travel. Do not apply excessive torque.
• From the end of travel, rotate the rotor 2 full turns and an additional half turn in the counter­clockwise direction. (The horn wire should end up at the top and the squib wire at the bottom.) Engage the clockspring locking mechanism.
CAUTION: Do not install steering wheel onto shaft of steering column assembly by driving it onto the shaft. Pull steering wheel down onto steering col­umn shaft using ONLY the steering wheel retaining nut.
Page 43
CLOCK SPRING WIR-ING LEADS STEERINGWHEEL
PL STEERING 19 - 43
REMOVAL AND INSTALLATION (Continued)
(13) Feed clock spring wiring leads through hole in steering wheel (Fig. 20). Position steering wheel on shaft of steering column assembly, making sure to fit flats on hub of steering wheel with formations on inside of clockspring.
Fig. 20 Steering Wheel Installation
(14) Install steering wheel to steering column shaft retaining nut and tighten until steering wheel is fully installed on shaft. The tighten steering wheel retaining nut to a torque of 61 N·m (45 ft. lbs.).
(15) Connect the clockspring electrical leads to components such as horn switches and speed control switches located in the steering wheel (Fig. 11).
(16) Install air bag electrical lead from clock spring, into connector on back of air bag module (Fig.
10). Be sure electrical connector from clock-
spring is securely latched into air bag module connector.
CAUTION: The fasteners, screws, and bolts, origi­nally used for the air bag components are specifi­cally designed for the air bag system. They must never be replaced with any substitutes. Anytime a new fastener is needed, replace only with correct fasteners provided in service packages or fasteners listed in the parts book.
(17) Install air bag module into center of steering wheel. Align air bag module mounting holes with bolt holes in steering wheel. Install only the 2 original or correct replacement air bag module attaching bolts (Fig. 9). Torque the 2 air bag module attaching bolts to 10 N·m (90 in. lbs.).
(18) Install key lock cylinder into lock housing. Key lock cylinder is installed by positioning key cyl-
inder in the run position so retaining tab can be depressed and the pushing key cylinder into lock hos­ing until retaining tab locks into key lock cylinder.
(19) Reconnect ground cable to Negative post of
the battery. When reconnecting battery on a
vehicle that has had the air bag module removed, the following procedure should be used.
• Remove forward console or cover as necessary.
• Connect DRB II to ASDM diagnostic 6-way con-
nector, located at right side of the ASDM module.
• Turn ignition key to ON position. Exit vehicle with the DRB II. Install the latest version of the proper diagnostic cartridge into the DRB II.
• Ensuring that their are no occupants in the vehicle, connect negative cable to negative post of the battery.
• Using the DRB II read and record active fault codes. Also read and record any stored fault codes. Refer to the Passive Restraint Diagnostic Test Man­ual if any faults are found.
• Erase stored faults if there are no active fault codes. If problems remain, fault codes will not erase.
• From the passenger side of the vehicle, turn ignition key to OFF and then ON observing instru­ment cluster air bag lamp. It should go on for six to eight seconds, then go out. This will indicate that the air bag system is functioning normally.
(20) If air bag warning lamp fails to light,
blinks on and off or goes on and stays on, there is an air bag system malfunction. Refer to the
Passive Restraint Diagnostic Test Manual to diag­nose the system malfunction.
(21) Test the operation of the horn, lights and any other functions that are steering column operated. If applicable reset the radio and the clock.
(22) Road test vehicle to ensure proper operation of the steering system and the speed control system.

SPECIFICATIONS

STEERING COLUMN FASTENER TORQUE SPECIFICATIONS

DESCRIPTION TORQUE Steering Wheel
Retaining Nut ...............61N·m(45ft.lbs.)
Steering Column Assembly
Upper Mounting Bracket
Attaching Nuts ...........17N·m(150 in. lbs.)
Page 44
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