steering DODGE NEON 1999 Service Repair Manual

weather temperature varies widely. Tire pressure will
decrease when the outdoor temperature drops.
Inflation pressures specified on the placard are
always the cold inflation pressure of the tire. Cold
inflation pressure is obtained after the vehicle has
not been operated for at least 3 hours, or the vehicle
is driven less than one mile after being inoperative
for 3 hours. Tire inflation pressures may increase
from 2 to 6 pounds per square inch (psi) during oper-
ation. Do not reduce this normal pressure build-up.
WARNING: OVER OR UNDER INFLATED TIRES
CAN AFFECT VEHICLE HANDLING. THE TIRE CAN
FAIL SUDDENLY, RESULTING IN LOSS OF VEHICLE
CONTROL.
TIRE PRESSURE FOR HIGH SPEED OPERATION
Chrysler Corporation advocates driving at safe
speeds within posted speed limits. Where speed lim-
its allow the vehicle to be driven at high speeds, cor-
rect tire inflation pressure is very important. For
speeds up to and including 120 km/h (75 mph), tires
must be inflated to the pressures shown on the tire
placard. For continuous speeds in excess of 120 km/h
(75 mph), tires must be inflated to the maximum
pressure specified on the tire sidewall.
Vehicles loaded to the maximum capacity should
not be driven at continuous speeds above 75 mph
(120 km/h).
For emergency vehicles that are driven at speeds
over 90 mph (144 km/h), special high speed tires
must be used. Consult tire manufacturer for correct
inflation pressure recommendations.
REPLACEMENT TIRES
The original equipment tires provide a proper bal-
ance of many characteristics such as:
²Ride
²Noise
²Handling
²Durability
²Tread life
²Traction
²Rolling resistance
²Speed capability
It is recommend that tires equivalent to the origi-
nal equipment tires be used when replacement is
needed.
Failure to use equivalent replacement tires may
adversely affect the safety and handling of the vehi-
cle.
The use of oversize tires not listed in the specifica-
tion charts may cause interference with vehicle com-
ponents. Under extremes of suspension and steering
travel, interference with vehicle components may
cause tire damage.WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
DIAGNOSIS AND TESTING
PRESSURE GAUGES
A quality air pressure gauge is recommended to
check tire pressure. After checking the air pressure,
replace valve cap finger tight.
TREAD WEAR INDICATORS
Tread wear indicators are molded into the bottom
of the tread grooves. When tread depth is 1.6 mm
(1/16 in.), the tread wear indicators will appear as a
13 mm (1/2 in.) band (Fig. 4).
Tire replacement is necessary when indicators
appear in two or more grooves or if localized balding
occurs.
TIRE WEAR PATTERNS
Under inflation will cause wear on the shoulders of
tire. Over inflation will cause wear at the center of
tire.
Excessive camber causes the tire to run at an
angle to the road. One side of tread is then worn
more than the other (Fig. 5).
Excessive toe-in or toe-out causes wear on the
tread edges and a feathered effect across the tread
(Fig. 5).
Fig. 4 Tread Wear Indicators
PLTIRES AND WHEELS 22 - 3
DESCRIPTION AND OPERATION (Continued)

Relocate the wheel on the mounting studs, two
studs over from the original position.
Retighten wheel nuts until all are properly
torqued. This will prevent brake distortion.
Check radial run out. If still excessive, mark tire
sidewall, wheel, and stud at point of maximum run
out (Fig. 6) and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
Rotating tire on wheel is particularly effective
when there is run out in both tire and wheel.
Remove tire from wheel and remount wheel on hub
in former position.
Check the radial run out of the wheel (Fig. 7). The
radial runout should be no more than 0.762 mm
(0.030 inch).
Check the lateral run out of the wheel (Fig. 8). The
lateral run out should be no more than 0.762 mm
(0.030 inch).
If the point of greatest wheel radial run out is near
the original chalk mark, remount the tire on the rim
180 degrees from its original position. Recheck therun out. If this does not reduce the run out to an
acceptable level, replace the wheel and/or the tire.
SERVICE PROCEDURES
TIRE AND WHEEL BALANCE
Balancing need is indicated by vibration of seats,
floor pan, or steering wheel. The vibration will be
noticed mostly when driving over 90 km/h (55 mph)
on a smooth road.
It is recommended that a two plane dynamic bal-
ancer be used when a wheel and tire assembly
require balancing. Static balancing should be used
only when a two plane balancer is not available.
Off-vehicle tire and wheel balancing is recom-
mended to be used on this vehicle.
NOTE: If on vehicle equipment is being used to bal-
ance the tire /wheel assemblies, remove the oppo-
site tire/wheel from the vehicle.
For static balancing, find the location of heavy spot
on tire/wheel causing the imbalance. Counter balance
wheel directly opposite the heavy spot. Determine
weight required to counterbalance the area of imbal-
ance. Place half of this weight on theinnerrim
flange and the other half on theouterrim flange
(Fig. 9).
For dynamic balancing, the balancing equipment is
designed to indicate the location and amount of
weight to be applied to both the inner and outer rim
flanges (Fig. 10).Fig. 6 Chalk Marking On Wheel, Tire And Stud
Fig. 7 Checking Wheel Radial Run Out
Fig. 8 Checking Wheel Lateral Run Out
22 - 10 TIRES AND WHEELSPL
DIAGNOSIS AND TESTING (Continued)

cranking. Whenever the Powertrain Control Module
(PCM) sets a Diagnostic Trouble Code (DTC) that
affects vehicle emissions, it illuminates the MIL. If a
problem is detected, the PCM sends a message over
the CCD Bus to the instrument cluster to illuminate
the lamp. The PCM illuminates the MIL only for
DTC's that affect vehicle emissions. The MIL stays
on continuously when the PCM has entered a
Limp-In mode or identified a failed emission compo-
nent or system. The MIL remains on until the DTC
is erased. Refer to the Diagnostic Trouble Code
charts in this group for emission related codes.
Also, the MIL either flashes or illuminates contin-
uously when the PCM detects active engine misfire.
Refer to Misfire Monitoring in this section.
Additionally, the PCM may reset (turn off) the MIL
when one of the following occur:
²PCM does not detect the malfunction for 3 con-
secutive trips (except misfire and fuel system moni-
tors).
²PCM does not detect a malfunction while per-
forming three successive engine misfire or fuel sys-
tem tests. The PCM performs these tests while the
engine is operating within6375 RPM of and within
10 % of the load of the operating condition at which
the malfunction was first detected.
STATE DISPLAY TEST MODE
The switch inputs to the Powertrain Control Mod-
ule (PCM) have two recognized states; HIGH and
LOW. For this reason, the PCM cannot recognize the
difference between a selected switch position versus
an open circuit, a short circuit, or a defective switch.
If the State Display screen shows the change from
HIGH to LOW or LOW to HIGH, assume the entire
switch circuit to the PCM functions properly. From
the state display screen, access either State Display
Inputs and Outputs or State Display Sensors.
CIRCUIT ACTUATION TEST MODE
The Circuit Actuation Test Mode checks for proper
operation of output circuits or devices the Powertrain
Control Module (PCM) may not internally recognize.
The PCM attempts to activate these outputs and
allow an observer to verify proper operation. Most of
the tests provide an audible or visual indication of
device operation (click of relay contacts, fuel spray,
etc.). Except for intermittent conditions, if a device
functions properly during testing, assume the device,
its associated wiring, and driver circuit work cor-
rectly.
DIAGNOSTIC TROUBLE CODES
A Diagnostic Trouble Code (DTC) indicates the
PCM has recognized an abnormal condition in the
system.
²The preferred and most accurate method of
retrieving a DTC is by using the DRB scan tool. The
scan tool supplies detailed diagnostic information
which can be used to more accurately diagnose
causes for a DTC.
Remember that DTC's are the results of a sys-
tem or circuit failure, but do not directly iden-
tify the failed component or components.
NOTE: For a list of DTC's, refer to the charts in this
section.
BULB CHECK
Each time the ignition key is turned to the ON
position, the malfunction indicator (check engine)
lamp on the instrument panel should illuminate for
approximately 2 seconds then go out. This is done for
a bulb check.
OBTAINING DTC'S USING DRB SCAN TOOL
(1) Connect the DRB scan tool to the data link
(diagnostic) connector. This connector is located in
the passenger compartment; at the lower edge of
instrument panel; near the steering column.
(2) Turn the ignition switch on and access the
ªRead Faultº screen.
(3) Record all the DTC's and ªfreeze frameº infor-
mation shown on the DRB scan tool.
(4) To erase DTC's, use the ªErase Trouble Codeº
data screen on the DRB scan tool.Do not erase any
DTC's until problems have been investigated
and repairs have been performed.
* Check Engine Lamp (MIL) will not illuminate if
this Diagnostic Trouble Code was recorded. Cycle
Ignition key as described in manual and observe code
flashed by Check Engine lamp.
Fig. 1 Data Link (Diagnostic) Connector
25 - 2 EMISSION CONTROL SYSTEMSPL
DESCRIPTION AND OPERATION (Continued)

HEX
CODEGENERIC
SCAN
TOOL
CODEDRB SCAN TOOL
DISPLAYDESCRIPTION OF DIAGNOSTIC TROUBLE CODE
66 P0133 Right Bank Upstream O2S
Slow ResponseOxygen sensor response slower than minimum required
switching frequency.
67 P0135 Right Rear (or just)
Upstream O2S Heater
FailureUpstream oxygen sensor heating element circuit
malfunction.
69 P0141 Right Rear (or just)
Downstream O2S Heater
FailureOxygen sensor heating element circuit malfunction.
6A P0300 Multiple Cylinder Mis-fire Misfire detected in multiple cylinders.
6B P0301 Cylinder #1 Mis-fire Misfire detected in cylinder #1.
6C P0302 Cylinder #2 Mis-fire Misfire detected in cylinder #2.
6D P0303 Cylinder #3 Mis-fire Misfire detected in cylinder #3.
6E P0304 Cylinder #4 Mis-fire Misfire detected in cylinder #4.
70 P0420 Right Rear (or just)
Catalyst Efficency FailureCatalyst efficiency below required level.
71 P0441 Incorrect Pruge Flow Insufficient or excessive vapor flow dtected during
evaporation emission system operation.
72 P1899 P/N Switch Stuck in Park
or in GearIncorrect input state detected for the Park/Neutral
switch, auto. trans. only.
73* P0551 Power Steering Switch
FailurePower steering high pressure seen at high speed (2.5L
only).
76 P0172 Right Rear (or just) Fuel
System RichA rich air/fuel mixture has been indicated by an
abnormally lean correction factor.
77 P0171 Right Rear (or just) Fuel
System LeanA lean air/fuel mixture has been indicated by an
abnormally rich correction factor.
7E P0138 Right Rear (or just)
Downstream O2S Shorted
to VoltageOxygen sensor input voltage maintained above the
normal operating range.
80 P0125 Closed Loop Temp Not
ReachedEngine does not reach 20ÉF within 5 minutes with a
vehicle speed signal.
81 P0140 Right Rear (or just)
Downstream O2S Stays at
CenterNeither reich or lean condition detected from the
downstream oxygen sensor.
84 P0121 TPS Voltage Does Not
Agree With MAPTPS signal does not correlate to MAP sensor.
85 P1390 Timing Belt Skipped 1
tooth or MoreRelationship between Cam and Crank signal is not
correct.
8A P1294 Target Idle Not Reached Actual idle speed does not equal target idle speed.
91 P1299 Vacuum Leak Found (IAC
Fully Seated)MAP sensor signal does not correlate to throttle position
sensor signal. Possible vacuum leak.
92 P1496 5 Volt Supply Output Too
Low5 volt output from regulator does not meet minimum
requirement.
94* P0740 Torq Conv Clu, No RPM
Drop At LockupRelationship between engine speed and vehicle speed
indicates no torque converter clutch engagement (auto.
trans. only).
PLEMISSION CONTROL SYSTEMS 25 - 5
DESCRIPTION AND OPERATION (Continued)

DIAGNOSIS AND TESTING
EGR SYSTEM ON-BOARD DIAGNOSTICS
The PCM performs an on-board diagnostic check of
the EGR system. The diagnostic system uses the
electronic EGR transducer for the system tests.
The diagnostic check activates only during selected
engine/driving conditions. When the conditions are
met, the PCM energizes the transducer solenoid to
disable the EGR. The PCM checks for a change in
the heated oxygen sensor signal. If the air-fuel mix-
ture goes lean, the PCM will attempt to enrichen the
mixture. The PCM registers a Diagnostic Trouble
Code (DTC) if the EGR system is not operating cor-
rectly. After registering a DTC, the PCM turns on the
malfunction indicator (Check Engine) lamp after 2
consecutive trips. There are 2 types of failures sensed
by the PCM. The first is a short or open in the elec-
trical solenoid circuit. the second is a mechhanical
failure or loss of vacuum. The Malfunction Indicator
Lamp (MIL) indicates the need for service.
If a problem is indicated by the MIL and a DTC for
the EGR system is set, check for proper operation of
the EGR system. Use the System Test, EGR Gas
Flow Test. If the EGR system tests properly, check
the system using the DRB scan tool. Refer to
On-Board Diagnosis sections in this Group. Also,
refer to the DRB scan tool and the appropriate Pow-
ertrain Diagnostics Procedure manual.
EGR SYSTEM TEST
WARNING: APPLY PARKING BRAKE AND/OR
BLOCK WHEELS BEFORE TESTING THE EGR SYS-
TEM.
(1) Check the condition of all EGR system hoses
and tubes for leaks, blockages, cracks, kinks and
hardening of rubber hoses. Repair and correct these
conditions before performing any tests.
(2) Be sure the hoses at both the EGR valve and
EGR valve control are connected to the proper fit-
tings (Fig. 3).
(3) Be sure the electrical connector is firmly con-
nected at the valve control.
(4) To check EGR system operation, connect the
DRB scan tool to the 16±way data link connector.
The data link connector is located on the lower edge
of the instrument panel near the steering column.
Refer to the appropriate Powertrain Diagnostic Pro-
cedures service manual for operation of the DRB
scan tool when diagnosing the EGR system.
(5) After checking the system with the DRB scan
tool, proceed to the following EGR Valve Leakage and
EGR Valve Control Tests and repair as necessary.
EGR GAS FLOW TEST
Use the following test procedure to determine if
exhaust gas is flowing through the EGR valve. It can
also be used to determine if the EGR tube is plugged,
or the system passages in the intake or exhaust man-
ifolds are plugged.
This is not to be used as a complete test of the
EGR system.
The engine must be started, running and warmed
to operating temperature for this test.
(1) All engines are equipped with two fittings
located on the EGR valve (Fig. 4). The upper fitting
(located on the vacuum motor) supplies engine vac-
uum to a diaphragm within the EGR valve for valve
operation. The lower fitting (located on the base of
the EGR valve) is used to supply exhaust back-pres-
sure to the EGR valve control.
(2) Disconnect the rubber hose at the vacuum
motor fitting (Fig. 4) on the top of the EGR valve
vacuum motor.
(3) Connect a hand-held vacuum pump to this fit-
ting.
(4) Start the engine.
(5) Slowly apply 5 inches of vacuum to the fitting
on the EGR valve motor.
(6) While applying vacuum, a minimum of 3 inches
of vacuum, and with the engine running at idle
Fig. 3 EGR Value and EGR Value ÐTypical
PLEMISSION CONTROL SYSTEMS 25 - 19

GROUP TAB LOCATOR
INIntroduction
INaIntroduction
0Lubrication and Maintenance
2Suspension
3Differential and Driveline
5Brakes
6Clutch
6aClutch
7Cooling
8ABattery
8BStarting
8CCharging System
8CaCharging System
8DIgnition System
8EInstrument Panel and Systems
8EaInstrument Panel and Systems
8FAudio System
8GHorns
8HVehicle Speed Control System
8HaVehicle Speed Control System
8JTurn Signal and Flashers
8KWindshield Wipers and Washers
8KaWindshield Wipers and Washers
8LLamps
8LaLamps
8MRestraint System
8NElectrically Heated Systems
8NaElectrically Heated Systems
8PPower Door Locks
8QaImmobilizer System
8SPower Windows
8TPower Mirrors
8TaPower Mirrors
8UChime Warning/Reminder System
8WWiring Diagrams - LHD and RHD
9Engine
9aEngine
11Exhaust System and Intake Manifold
11aExhaust System and Intake Manifold
13Frame and Bumpers
13aFrame and Bumpers
14Fuel System
14aFuel System - 1.8L Engine
19Steering
19aSteering
21Transaxle
21aTransaxle
22Tires and Wheels
23Body
24Heating and Air Conditioning
25Emission Control Systems
25aEmission Control System - 1.8L Engine