QuestionI recently purchased a 1996 Caravan (3.8L- 2WD) in need of a new power steering pump. I have successfully disconnected the old pump, but cannot find space to remove it, much less get the new pump and pulley in place. What is the best way to make room for the swap (what else do I have to pull)? Thanks for any light you can shed on the issue.
Answer3.3/3.8 LITER POWER STEERING PUMP
REMOVE
WARNING: POWER STEERING OIL, ENGINE COMPONENTS AND THE 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 the (-) negative battery cable from the battery and isolate cable.
Raise vehicle on jack stands 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.
Disconnect the oxygen sensor wiring harness from the vehicle wiring harness. Access to connection at vehicle wiring harness is through the oxygen sensor wiring harness grommet in the floor pan of the vehicle
NOTE: The exhaust system needs to be removed from the engine to allow for an area to remove the power steering pump from the vehicle.
Remove the catalytic converter from the exhaust manifold. Then remove all the exhaust system hangers/isolators from the brackets on the exhaust system.
Move the exhaust system as far rearward and to the left side of the vehicle as possible Exhaust Position For Removing Power Steering Pump .
Raise the insulating wrap on the power steering hoses to expose the hose to steel tube connection. Remove the hose from the power steering fluid return line on the front suspension cradle Power Steering Return Hose At Return Line. . Allow the power steering fluid to drain from the pump through the removed hose.
Remove the accessory drive splash shield Accessory Drive Splash Shield .
Remove the serpentine accessory drive belt from the engine Serpentine Drive Belt And Routing. . See Cooling, Group 7 for detailed removal procedure.
Remove the power steering fluid supply hose coming from the remote fluid reservoir, from the fitting on the power steering pump Power Steering Hoses At Power Steering Pump . Drain off excess power steering fluid from hose.
Remove the power steering fluid pressure line Power Steering Hoses At Power Steering Pump from the power steering pump. Drain excess power steering fluid from tube.
Remove the power steering fluid return hose Power Steering Hoses At Power Steering Pump from the power steering pump. Drain excess power steering fluid from tube.
Remove the support bracket at the rear of the power steering pump attaching the pump to the rear of the engine Power Steering Pump Support Bracket .
Remove the 3 bolts mounting the power steering pump to the alternator/power steering pump and belt tensioner mounting bracket Power Steering Pump Mounting Bolts .
Remove the power steering pump from its mounting bracket.
The power steering pump is removed from the vehicle by pulling it out through the exhaust tunnel area in the floor pan of the vehicle.
INSTALL
Install power steering pump back in vehicle using the reverse order of its removal through the exhaust tunnel are of the vehicle.
Install the power steering pump on its mounting bracket. Install the 3 power steering pump mounting bolts Power Steering Pump Mounting Bolts . Tighten the power steering pump mounting bolts to a torque of 54 N·m (40 ft. lbs.).
Install the support bracket attaching rear of power steering pump to engine Power Steering Pump Support Bracket . Tighten the nut and bolt holding the strut assembly to bracket and the intake manifold stud to a torque of 54 N·m (40 ft. lbs).
Install the power steering fluid pressure line onto the output fitting of the power steering pump Power Steering Hoses At Power Steering Pump . Tighten the pressure line to pump fitting tube nut to a torque of 31 N·m (275 in. lbs.). Before connecting the pressure line to power steering pump inspect the O-ring on the pressure line for damage.
Install the power steering fluid, low pressure return hose on the power steering pump low pressure fitting Power Steering Hoses At Power Steering Pump . Be sure hose clamps are properly reinstalled.
Install the power steering fluid supply hose from the power steering fluid reservoir, on the power steering pump fluid fitting Power Steering Hoses At Power Steering Pump . Be sure hose is clear of accessory drive belts and all hose clamps are properly reinstalled.
Install the serpentine drive belt Serpentine Drive Belt And Routing. . See Cooling, Group 7 for detailed installation procedure
CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses Power Steering Return Hose At Return Line. .
Install the hose on the power steering fluid return line on the front suspension cradle Power Steering Return Hose At Return Line. . Be sure hose clamps are properly reinstalled.
Install the exhaust pipe on the exhaust manifold. Install all exhaust system hangers/isolators on the exhaust system brackets.
Connect the oxygen sensor wiring harness to the vehicle wiring harness. Install wiring harness grommet in the floor pan of the vehicle.
Install the accessory drive splash shield Accessory Drive Splash Shield .
Lower vehicle
CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar®, Power Steering Fluid, or equivalent.
Fill the remote power steering pump fluid reservoir to correct fluid level.
Connect the negative battery cable on the negative battery post.
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
