I'm starting a new Stratus DIY information. If you have a problem with your stratus. Please post them on the open forum, This way someone maybe able to help you. This DIY section will used for information on either how do I replace valve cover gaskets to TSB's and recall. I will move any post, that is not part of the DIY section. I am also open for any input.

 

SUBJECT:
Transaxle Slips In Reverse Or First Gear
OVERVIEW:
This bulletin involves replacing the low/reverse accumulator cover and
O-ring during transmission repair.
MODELS:
2002 (JR) Sebring Sedan/Sebring Convertible/Stratus Sedan
2002 (PL) Neon
2002 (PT) PT Cruiser
2002 (RS) Town & Country/Voyager/Caravan
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN AUTOMATIC
TRANSAXLE WITH BUILD CODE DATES OF 1342 (MAY 14, 2002) THROUGH
AND INCLUDING 1502 (MAY 30, 2002). REFER TO THE APPROPRIATE
SERVICE MANUAL OR MDS2 SERVICE INFORMATION FOR THE TRANSAXLE
LABEL LOCATION AND CODE INFORMATION.
SYMPTOM/CONDITION:
Some vehicles may have a transaxle that will not move or slips in Reverse or First gear.
DISCUSSION:
Vehicles equipped with automatic transaxles built in the range specified that exhibit
the condition(s) listed above may also have Diagnostic Trouble Code(s) (DTC)
P0736, Gear Ratio Error In Reverse, or P0731, Gear Ratio Error In 1st set. All
vehicles that fall in this category must have the Low/Reverse Accumulator
Cover and O-Ring replaced during transmission repair.
PARTS REQUIRED:
Qty. Part No. Description
1 04431617 Cover, Low/Reverse Accumulator
1 06501549 O-Ring, Low/Reverse Accumulator

 

INSTALLATION - TIMING BELT For the 2.4 Engines
Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing.
Set camshafts timing marks so that the exhaust camshaft sprocket is a 1/2 notch below the intake camshaft sprocket (Camshaft Sprocket Alignment).
CAUTION: Ensure that the arrows on both camshaft sprockets are facing up.

Install timing belt. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner (Timing Belt Installation).
Move the exhaust camshaft sprocket counterclockwise (Timing Belt Installation) to align marks and take up belt slack.
Insert a 6 mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley. Rotate the top plate COUNTERCLOCKWISE . The tensioner pulley will move against the belt and the tensioner setting notch will eventually start to move clockwise. Watching the movement of the setting notch, continue rotating the top plate counterclockwise until the setting notch is aligned with the spring tang (Timing Belt Tension Adjustment). Using the allen wrench to prevent the top plate from moving, torque the tensioner lock bolt to 25 N·m (220 in. lbs.). Setting notch and spring tang should remain aligned after lock nut is torqued.
Remove allen wrench and torque wrench.
NOTE: Repositioning the crankshaft to the TDC position must be done only during the CLOCKWISE rotation movement. If TDC is missed, rotate a further two revolutions until TDC is achieved. DO NOT rotate crankshaft counterclockwise as this will make verification of proper tensioner setting impossible.

Rotate the crankshaft CLOCKWISE two complete revolutions manually for seating of the belt, until the crankshaft is repositioned at the TDC position. Verify that the camshaft and crankshaft timing marks are in proper position (Crankshaft and Camshaft Timing).
Check if the spring tang is within the tolerance window (Timing Belt Tension Verification). If the spring tang is within the tolerance window, the installation process is complete and nothing further is required. If the spring tang is not within the tolerance window, repeat Steps 5 through 7.
Install engine mount support bracket (Front Timing Belt Covers).
Install upper timing belt cover. Torque fasteners to 6 N·m (50 in. lbs.)
Install the lower timing belt cover. Torque fasteners to 6 N·m (50 in. lbs.)
Install generator and bracket. Connect generator connections.
Install AC/Generator belt tensioner.
Install crankshaft damper.
Install right engine mount.
Install coolant recovery container.
Install accessory drive belts.
Install belt splash shield.
Install right front wheel.
Connect negative battery cable.

 

SUBJECT:
Revised Rear Suspension Lateral Control Links
MODELS:
2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan
DISCUSSION:
A change to the rear suspension rear lateral control links is scheduled to enter
production on or about August 6, 2003. The change involves using non-adjustable
rear suspension rear lateral control links that do not allow adjustments to be
made to the rear suspension camber setting.
In the unlikely instance that the rear suspension camber should become out of specification,
adjustable rear suspension rear lateral control links have been released for service
(Individual camber specification is: -1.1 to 0.1 degrees. Cross camber specification is: -1.0
to +1.0). For vehicles with suspension sales codes SDA, SDC or SDE use adjustable rear
suspension rear lateral control link p/n 05135565AA and for vehicles with suspension sales
code SDD use adjustable rear suspension rear lateral control link p/n 05135566AA.
Use the service procedures outlined on TechCONNECT for rear suspension rear
lateral control link replacement and suspension alignment.
For vehicles originally built with adjustable rear lateral control links continue to
use p/n 04764965AA for sales codes SDA, SDC and SDE or p/n 04764961AA
for sales code SDD if link replacement is ever necessary.

 

DESCRIPTION
The 2.4 Liter (148 cu. in.) in-line four cylinder engine is a double over head camshaft with hydraulic lifters and four valve per cylinder design (2.4 Liter Engine). The engine is free-wheeling; meaning it has provisions for piston-to-valve clearance. However valve-to-valve interference can occur, if camshafts are rotated independently.

The cylinders are numbered from front of the engine to the rear. The firing order is 1–3–4–2.

The engine identification number is located on the rear of the cylinder block (Engine Identification).

 

INSTALLATION - TIMING BELT
Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing.
Set camshafts timing marks so that the exhaust camshaft sprocket is a 1/2 notch below the intake camshaft sprocket (Camshaft Sprocket Alignment).
CAUTION: Ensure that the arrows on both camshaft sprockets are facing up.

Install timing belt. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner (Timing Belt - Installation).
Move the exhaust camshaft sprocket counterclockwise (Timing Belt - Installation) to align marks and take up belt slack.
NOTE: A new tensioner is held in the wound position by a pull pin.

Remove the pull pin or Allen wrench from the belt tensioner.
Once the timing belt has been installed and tensioner released, rotate the crankshaft two (2) complete revolutions. Verify that the TDC marks on crankshaft and timing marks on the camshafts are aligned.
Install engine mount support bracket (Front Timing Belt Covers).
Install upper timing belt cover. Torque fasteners to 9 N·m (80 in. lbs.) (Front Timing Belt Covers).
Install the lower timing belt cover. Torque fasteners to 9 N·m (80 in. lbs.) (Front Timing Belt Covers).
Install generator and bracket. Connect generator connections.
Install AC/Generator belt tensioner.
Install crankshaft damper.
Install right engine mount.
Install coolant recovery container.
Install accessory drive belts.
Install belt splash shield.
Install right front wheel.
Connect negative battery cable.

 

TIMING BELT
CAUTION: The 2.5L engine is a Non-freewheeling design. When the timing belt is removed, DO NOT rotate the camshafts or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage.

REMOVAL
Remove timing belt covers. Refer to procedure in this section.
Mark timing belt running direction for installation Timing Belt System Mark Direction of Timing Belt
Loosen timing belt tensioner center bolt Timing Belt Engine Sprocket Timing and remove auto tensioner.
Remove timing belt
CAUTION: Coolant or oil leakage on timing belt will shorten its life drastically. If timing belt is seriously contaminated, it must be replaced. Clean all components and correct source of leak.

CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE
TIMING BELT TENSIONER
When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body.
Place the tensioner into a vise and slowly compress the plunger Timing Belt Tensioner Compressing
CAUTION: Index the tensioner in the vise the same way it is installed on the engine. This is to ensure proper locking pin orientation when tensioner is installed on the engine.

When plunger is compressed into the tensioner body, install a locking pin through the body and plunger Timing Belt Tensioner Compressing
INSTALLATION
Set crankshaft sprocket to TDC by aligning the sprocket mark with the mark on the oil pump housing. Then rotate crankshaft 3 notches before TDC Crankshaft Sprocket Timing
Set camshaft sprockets to the aligning marks on the sprockets with the marks on the rear timing belt cover Camshaft Sprocket Timing
Install timing belt on right camshaft sprocket. Install a binder clip on the belt and sprocket so the belt will not slip out of position. Keeping the belt taught, install belt under the water pump pulley and then around the left camshaft sprocket. Install an additional binder clip on the left sprocket and belt.
Rotate the crankshaft to TDC Adjusting Crankshaft Sprocket for Timing Belt Continue routing the belt around the idler pulley, crankshaft sprocket, and tensioner pulley.
To tension belt perform the following:
Apply rotating force to the crankshaft sprocket in the clockwise direction, check that all timing marks are aligned.
Loosen tensioner pulley center bolt.
Using Special Tool MD 998767 and a torque wrench on the tensioner pulley. Apply 4.4 N·m (38.9 in. lbs.) of torque to tensioner Timing Belt Tension Adjustment Tighten tensioner pulley bolt to 48 N·m (35 ft. lbs.)
With torque being applied to the tensioner pulley, install the hydraulic tensioner to the tensioner pulley bracket. Tighten tensioner fasteners to 23 N·m (205 in. lbs.)
Pull tensioner plunger pin
Rotate crankshaft 2 revolutions in a clockwise direction ONLY and check the alignment of the timing marks Timing Belt Engine Sprocket Timing Install tensioner pin into assembly. The pin should slide in and out without any resistance. If the pin does not slide freely, perform the procedure again.
Install timing belt covers. Refer to procedure in this section.
Install right engine mount. Refer to procedure in this section.
Install crankshaft damper and crankshaft damper bolt. Tighten to 182 N·m (134 ft. lbs.)
Install accessory drive belts.
Raise vehicle on hoist and install drive belt splash shield.

 

2002 stratus steering gear. REMOVAL
NOTE: Before proceding, review Warnings and Cautions.

Remove remote ground cable from ground stud on left shock tower. Then correctly isolate ground cable from vehicle by installing isolator on stud (Correctly Isolated Remote Ground Cable).
Siphon as much power steering fluid as possible from the remote power steering fluid reservoir.
Place the steering wheel and front wheels in the STRAIGHT-AHEAD position. Lock the steering wheel in this position using a steering wheel holder.
Under the instrument panel, disconnect the intermediate shaft from the steering gear shaft. To do so, remove the pinch bolt from the intermediate shaft coupler (Intermediate Shaft Attachment), then slide the intermediate shaft up and off the steering gear shaft.
Raise vehicle.
Remove both front wheel and tire assemblies.
Remove fasteners attaching drive belt splash shield to crossmember.
Remove nuts attaching both outer tie rod ends to steering knuckles. Remove tie rod end nuts by holding tie rod end stud with a socket while loosening and removing nut with wrench (Removing Tie Rod End Nut).
Remove both tie rod end studs from steering knuckles using Remover, Special Tool C-3894-A.
CAUTION: This vehicles 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 relation to the vehicle body. This process is carried out when building the vehicle by accurately locating the front suspension crossmember to master gage holes located in the underbody of the vehicle. Consequently, 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 to keep the alignment settings the same. Therefore, before removing the front suspension crossmember from the vehicle, locating marks for the front suspension crossmember MUST be scribed on the front suspension crossmember and body of vehicle as described in the following steps. If location of front suspension crossmember to body is not maintained when vehicle is assembled, vehicle handling and or tire wear problems may occur.

Using an awl, scribe lines on the body marking the front-to-rear and side-to-side location where the front suspension crossmember is mounted against the body of the vehicle. at all four locations where the crossmember mounts. The line should be scribed at all locations where the crossmember is mounted to the vehicle on each side of the vehicle.
Remove the stabilizer bar bushing clamp-to-body attaching bolts (Stabilizer Bar Bushing Clamp Attaching Bolts). The stabilizer bar bushing clamp -to-crossmember bolts do not need to be removed.
Remove the bolts attaching the shock absorber clevis to the left and right lower control arms (Shock Clevis To Lower Control Arm Bolts).
Remove 3 bolts attaching engine torque mount to crossmember.
Remove screws fastening steering gear heat shield to crossmember (Pressure Hose Mounting To Crossmember).
Remove screws fastening power steering pressure hose to crossmember (Pressure Hose Mounting To Crossmember).
Remove brake tube routing bracket from left lower control arm rear mounting bolt.
Disconnect fuel tube bundle routing support above crossmember.
Position transmission jack under center of front suspension crossmember to support it.
On each side of the vehicle, remove the 2 bolts attaching the front and rear of the front suspension crossmember to the frame rails of vehicle (Crossmember To Body Attaching Bolts).
Using transmission jack, lower front suspension crossmember enough to allow steering gear to be removed from crossmember. When lowering front suspension crossmember, do not let crossmember hang from lower control arms, weight of crossmember must be supported by the transmission jack.
Remove power steering pressure and return hoses from the power steering gear fluid ports (Power Steering Pressure And Return Hose At Steering Gear).
Remove wiring harness connector from the power steering fluid pressure switch.
Remove 4 bolts fastening power steering gear to front suspension crossmember. Remove power steering gear from front suspension crossmember.
Transfer required parts from removed gear to the replacement gear if a new gear is being installed.

 

POWER STEERING GEAR ASSEMBLY THIS IS FOR 1998 STRATUS
REMOVE
Remove remote ground cable Remote Ground Cable At Shock Tower from ground stud on shock tower. Then correctly isolate ground cable from vehicle by installing isolator on stud Correctly Isolated Remote Ground Cable
Siphon as much power steering fluid as possible from the remote power steering fluid reservoir.
From interior of vehicle, remove the retaining pin from the intermediate shaft coupler pinch bolt Intermediate Shaft Coupler To Steering Gear Attachment Then remove the pinch bolt Intermediate Shaft Coupler To Steering Gear Attachment from the intermediate shaft coupler and the separate intermediate shaft coupler, from steering gear shaft.
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.
Remove both front wheel and tire assemblies from the vehicle.
Remove nuts attaching both outer tie rod ends to the steering knuckles Removing Tie Rod End Nut 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 Removing Tie Rod End Nut
Remove both tie rod end studs, from the steering knuckles, using Remover, Special Tool MB-991113 Tie Rod End Removal From Steering Knuckle
CAUTION: This vehicles 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 relation to the vehicle body. This process is carried 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 necessary or possible to adjust a vehicles front suspension alignment settings. Consequently, 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.

CAUTION: Before removing the front suspension crossmember from the vehicle, locating marks for the front suspension crossmember MUST be scribed on the front suspension crossmember and body of vehicle. This must be done so front suspension crossmember can be located against body of vehicle, in the same location when it is installed back in vehicle. 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.

NOTE: Use the following procedure to mark the side to side and front to back installed location of the front suspension crossmember to the body of the vehicle.

Using an awl, scribe a line on the body Front Suspension Crossmember Front To Back Locating Mark (Left Side Front) and Front Suspension Crossmember Front To Back Locating Mark (Left Side Rear) marking the front to back installed location where the front suspension crossmember is mounted against the body of the vehicle. The line should be scribed at both the front and back of where the crossmember is mounted to the vehicle and on each side of the vehicle. In Front Suspension Crossmember Front To Back Locating Mark (Left Side Front) and Front Suspension Crossmember Front To Back Locating Mark (Left Side Rear) the left side of the vehicle is shown.
Using an awl, scribe a line on the front suspension crossmember Front Suspension Crossmember Side To Side Locating Mark marking the side to side installed location where front suspension crossmember is mounted against the body of the vehicle. The line should be scribed at the side of the frame rail bracket Front Suspension Crossmember Side To Side Locating Mark where the crossmember is mounted to the vehicle. The locating mark is to be marked the same on each side of the vehicle. In Front Suspension Crossmember Side To Side Locating Mark the left side of the vehicle is shown.
Remove the stabilizer bar bushing clamp to body attaching bolts only Stabilizer Bar Bushing Clamp Attaching Bolts The sway bar bushing clamp to front suspension crossmember bolts Stabilizer Bar Bushing Clamp Attaching Bolts do not need to be removed.
If vehicle is equipped with antilock brakes, the hydraulic control unit can not hang from the brake tubes when lowering front suspension crossmember. Using wire, tie the antilock brakes hydraulic control unit to the body and engine so the wire will support it when the crossmember is lowered.
If vehicle is equipped with antilock brakes, remove the 3 bolts attaching the antilock brakes hydraulic control unit to the front suspension crossmember.
Remove the bolts attaching the shock absorber clevis to the left and right lower control arms Shock Clevis To Lower Control Arm Bolts
Remove the 2 bolts attaching the under engine support bracket Engine Support Bracket To Crossmember Attaching Bolts to the front edge of the front suspension crossmember.
Remove the 2 attaching bolts from the rear support bracket Rear Support Bracket Attachment To Crossmember at the rear of the front suspension crossmember.
Remove bolt Engine Support Bracket To Transaxle Bracket Bolt attaching engine support bracket to the transaxle mounting bracket.
Position a transmission jack under the center of the front suspension crossmember. Transmission jack is used to lower, support and raise front suspension crossmember when removing steering gear assembly.
From each side of the vehicle, remove the 2 bolts attaching the front and rear of the front suspension crossmember to the frame rails of vehicle Crossmember To Body Attaching Bolts
Using transmission jack, lower front suspension crossmember enough to allow steering gear to be removed from crossmember. When lowering front suspension crossmember, do not let crossmember hang from lower control arms, weight of crossmember must be supported by the transmission jack.
Remove power steering fluid, pressure and return hoses from the power steering gear assembly Power Steering Pressure And Return Hose At Steering Gear
Remove wiring harness connector, Power Steering Pressure And Return Hose At Steering Gear from the power steering fluid pressure switch.
Remove the 2 bolts, at the isolators Steering Gear Rear Mounting Isolator Bolt and Steering Gear Front Mounting Bolt attaching the steering gear assembly to front suspension crossmember. Then remove the 2 bolts attaching the steering gear saddle bracket Steering Gear Saddle Bracket Mounting Bolts to the front suspension crossmember. Remove the steering gear assembly from the front suspension crossmember.
Transfer required parts from removed steering gear assembly to the replacement steering gear, if a new steering gear is being installed.
INSTALL
Install steering gear assembly on front suspension crossmember. Install the 2 long steering gear assembly to front crossmember mounting bolts Steering Gear Rear Mounting Isolator Bolt and Steering Gear Front Mounting Bolt into the mounting isolators. Then install the 2 short bolts Steering Gear Saddle Bracket Mounting Bolts into the saddle bracket. Tighten the 4 steering gear mounting bolts to a torque of 68 N·m (50 ft. lbs.)
Install the power steering fluid pressure and return lines on the ports of the power steering gear Power Steering Pressure And Return Hose At Steering Gear Tighten power steering fluid pressure and return lines to steering gear tube nuts Power Steering Pressure And Return Hose At Steering Gear to a torque of 31 N·m (275 in. lbs.)
Using transmission jack, raise front suspension crossmember and steering gear against body of vehicle. Start the 2 rear bolts Crossmember To Body Attaching Bolts into tapping plates, attaching front suspension crossmember to body of vehicle. Then install the 2 front bolts, Crossmember To Body Attaching Bolts attaching front suspension crossmember to frame rails of vehicle. Tighten the 4 mounting bolts evenly, 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 scribed into body of vehicle. This MUST be done to maintain NET BUILD front suspension alignment settings.

Using a soft face hammer, tap front suspension crossmember into position, until it is aligned with the previously scribed positioning marks on body of vehicle Front Suspension Crossmember Front To Back Locating Mark (Left Side Front) , Front Suspension Crossmember Front To Back Locating Mark (Left Side Rear) and Front Suspension Crossmember Side To Side Locating Mark When front suspension crossmember is correctly positioned, torque the 2 rear crossmember 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.)
Install the engine support bracket on the front of the front suspension crossmember Engine Support Bracket To Crossmember Attaching Bolts Install the 2 support bracket to suspension crossmember attaching bolts and tighten to a torque of 75 N·m (55 ft. lbs.)
Install bolt Engine Support Bracket To Transaxle Bracket Bolt attaching engine support bracket to transaxle mounting bracket. Tighten bolt to a torque of 75 N·m (55 ft. lbs.)
Install the 2 bolts attaching the rear support bracket, for the under engine support bracket Rear Support Bracket Attachment To Crossmember , to the rear of the front suspension crossmember. Tighten bolts to a torque of 75 N·m (55 ft. lbs.)
Install vehicle wiring harness connector Power Steering Pressure And Return Hose At Steering Gear onto power steering fluid pressure switch on steering gear assembly. Be sure locking tab on wiring harness connector is securely latched to pressure switch.
Install the antilock brakes hydraulic control unit mounting bracket on the front suspension crossmember. Install the 3 mounting bracket to crossmember attaching bolts and tighten to a torque of 28 N·m (250 in. lbs.)
Loosely install the 2 shock absorber clevis to lower control arm attaching nuts and bolts Shock Clevis To Lower Control Arm Bolts
Install tie rod seal boot heat shield Tie Rod End Removal From Steering Knuckle on tie rod end.
Install tie rod end into steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut Tie Rod End Removal From Steering Knuckle Then using a crowfoot and 11/32 socket, torque tie rod end attaching nut to 61 N·m (45 ft. lbs.) Torquing Tie Rod End Attaching Nut
Install the 2 stabilizer bar bushing clamp to body attaching bolts Stabilizer Bar Bushing Clamp Attaching Bolts and securely tighten
CAUTION: When supporting lower control arm with jack stand, do not position jack stand under the ball joint cap on the lower control arm. Position in area of lower control arm shown in Lower Control Arm Correctly Supported By Jack Stand

Lower vehicle to the ground with a jack stand positioned under the lower control arm Lower Control Arm Correctly Supported By Jack Stand Continue to lower vehicle so the total weight of the vehicle is supported by the jack stand and lower control arm.
Tighten the shock absorber clevis to lower control arm bushing thru-bolt Shock Clevis To Lower Control Arm Bolts to a torque of 92 N·m (68 ft. lbs.)
Install the wheel and tire assemblies back on vehicle. Tighten the wheel nuts in proper sequence to a torque of 129 N·m (95 ft. lbs.) torque
CAUTION: Before connecting steering column intermediate shaft coupler onto steering gear shaft, front wheels must be pointed straight ahead and steering wheel must be in center position.

From interior of vehicle, reconnect the steering column intermediate shaft coupler on the steering gear shaft Intermediate Shaft Coupler To Steering Gear Attachment Install a new steering gear coupler retaining pinch bolt and torque to 27 N·m (240 in. lbs.) Be sure to install the upper to lower steering coupler retaining bolt, retention pin.
CAUTION: Do not use automatic transmission fluid.

Fill power steering pump fluid reservoir to the (Full-Cold) proper level.
Start the engine and let run for a few seconds. Then turn the engine off.
Add fluid if necessary.
Raise front wheels of vehicle off the ground.
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 Mopar®, Power Steering Fluid, or equivalent. See Checking Fluid Level.
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.

Check front alignment and adjust the front Toe setting on the vehicle.
Tighten tie rod jam nut to 74 N·m (55 ft.lbs.) torque.
Adjust steering gear to tie rod boots at tie rods.

 

OPERATION
The Chrysler fuel pump module is an in-tank unit with an integral fuel level sensor and pressure regulator. The pump is driven by a 12 volt DC motor any time the fuel pump relay is energized. Serviceable components on the module include:

Inlet strainer
Fuel level sensor
Fuel Filter/Pressure regulator
The pump draws fuel through a strainer and pushes it through the motor to the outlet. The pump contains two check valves. One valve relieves internal fuel pump pressure and regulates maximum pump output. The second valve, in the pump outlet, maintains pump pressure during engine off conditions.

The fuel system use a positive displacement, gerotor, with a permanent magnet electric motor. This fuel system does not contain the traditional fuel return lines. The regulator contains a calibrated spring which forces a diaphragm against the fuel filter return port. When pressure exceeds the calibrated amount, the diaphragm retracts, allowing excess pressure and fuel to vent into the tank.

The maximum deadhead pressure is approximately 880 kPa (130 psi). The regulator adjusts fuel system pressure to approximately 400 ±34 kPa (58 ± 5 psi).

The inlet strainer, level sensor and fuel pressure regulator/filter are the only serviceable items.