Mechanics

DRIVEBELT AND POWERSTEERING PUMP

2004 Dodge Caravan

Engine Mechanical problem
2004 Dodge Caravan 6 cyl Front Wheel Drive Automatic 51000 miles

My Dodge Grand caravan is a 3.3L engine.
I have a repair manual however it doesn; t peroperly describe
1. Removal of drivebelt (this engine has automatic tensioner)
2. Change of power steering pump

Could you describe the removal and change ofboth issues?
Avatar
Maltusch
September 17, 2009.




Hello maltusch

Here is your request:
1.Remove and isolate the negative battery cable.

2.Raise and safely support the vehicle. Place a drain pan under the power steering pump.

3.Disconnect the wiring harness connector to the oxygen sensor which is accessible through the oxygen sensor wiring harness grommet in the vehicle floor pan.

4.Remove the catalytic converter from the exhaust manifold and remove all exhaust system hangers and isolators from the exhaust system brackets. Move exhaust system out of the way as far rearward and to the left as possible to provide access to the power steering pump.

5.Remove the power steering fluid return line hose on the front suspension cradle. Allow the fluid to drain from the pump and hose.

6.Remove the accessory drive belt splash shield.

7.Remove accessory drive belt.

8.Disconnect the power steering remote reservoir supply hose from the fitting on the power steering pump. Allow fluid to drain from the hose.

9.Remove power steering fluid pressure line from the power steering pump and drain any excess power steering fluid.

10.Remove the power steering fluid return hose from the power steering pump.

11.Remove the rear support bracket mounted behind the power steering pump to the engine block.

12.Remove the 3 mounting bolts that secure the pump to the alternator/power steering pump and belt tensioner mounting bracket.

13.Remove the power steering pump and pulley assembly from the vehicle. Transfer all required parts from the pump to the new replacement pump before installation.

Installation

To install:
1.Position the front of the power steering pump up onto the mounting bracket. Torque the 3 power steering pump-to-mounting bracket bolts to 40 ft. lbs. (54 Nm).

2.Install the rear power steering pump-to-engine block support bracket. Torque the support bracket mounting bolts to 40 ft. lbs. (54 Nm). Install the nut to the mounting stud behind the pump and torque to 40 ft. lbs. (54 Nm).

3.Install the high pressure fluid line to the pump output fitting. Torque the high pressure line-to-power steering pump fitting to 275 inch lbs. (31 Nm). Be sure to inspect the pressure line O-ring for any damage before connecting the pressure line to the steering pump.

4.Install the low pressure power steering fluid hose to the power steering pump low pressure fitting. Be sure the hose clamps are properly reinstalled and hoses are clear of the accessory drive belts.

5.Install the accessory drive belt.

6.Install the hose on the power steering fluid return line on the front suspension cradle. Be sure the hose clamps and heat shield tubes are correctly reinstalled.

7.Reconnect the exhaust pipe to the exhaust manifold. Install the hangers and isolators onto the exhaust system brackets. Torque the nuts and bolts to 250 inch lbs. (28 Nm).

8.Reconnect the wiring harness connectors to the oxygen sensor. Install the wiring harness grommet into the vehicle floor pan.

9.Install the accessory drive belt splash shield.

10.Remove the drain pan and lower the vehicle.

11.Refill the power steering pump reservoir with the correct amount of clean power steering fluid.

12.Reconnect the negative battery cable. Bleed the power steering system.

13.Run the engine and check the system for leaks and proper steering operation.

here are some pics:


http://www.2carpros.com/forum/automotive_pictures/46384_dodge_caravan1_1.jpg




http://www.2carpros.com/forum/automotive_pictures/46384_power_steering1_1.jpg




http://www.2carpros.com/forum/automotive_pictures/46384_power_steering2_1.jpg



Removal & Installation of drivebelt

1.
Disconnect the negative battery cable.

2.Raise the front of the vehicle and safely support it with jackstands.

3.Remove the right front splash shield.

4.Release tension by rotating the tensioner clockwise.

5.Remove the belt and install a replacement.

6.Proper belt tension is maintain by the dynamic tension.

7.Install the right front splash shield. Lower the front of the vehicle.

8.Connect the negative battery cabl

good luck
AD

Tiny
Mathiaso
Sep 17, 2009.
I saw the response and the pictures, however my engine has a horizontal automatic tensioner.
Should slightly release the bolt or remove it complete to release the tension?

Tiny
Maltusch
Sep 18, 2009.
Yes, turn the bolt clockwise to release the tension

Tiny
Mathiaso
Sep 18, 2009.
Hi!
Not absolutely correct description up. As my engine is like the 3.8l

Again I checked the setup of the pump. The powersteering pump is connected to a bracket which is in one piece connecting to the other parts. It means I can not remove the bracket. The removal of catlusator is not needed I think as it seems does not provide more space.
I think one needs to unscrew the power pump through the holes of the disc? Is this so and do u have pictures?
Tensioner- should the tensioner be moved up or down after releasing the bolt slightly?
Tx. Micke

Tiny
Maltusch
Sep 21, 2009.

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