engine DODGE NEON 1999 Service Repair Manual

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 neg-
ative 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.
(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 lock-
ing tab on power steering pressure switch.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 sys-
tem. Stop engine, check fluid level, and inspect sys-
tem 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 compo-
nents.
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 DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
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 num-
bers 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. 7 Power Steering Pressure Switch Location On
Steering Gear
Fig. 8 Power Steering Hose Routing Bracket
PLSTEERING 19 - 13
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.
(4) Remove power steering pressure hose from
routing clip on generator shield (Fig. 10).
(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 compart-
ment.
(9) Discard all used O-rings located at ends of
power steering pressure hose and Banjo bolt.
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 pres-
sure 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.
Fig. 9 Power Steering Pressure Hose At Steering
Gear
Fig. 10 Power Steering Pressure Hose Routing Clip
At Generator Shield
Fig. 11 Power Steering Hose Attachment To
Generator Shield
Fig. 12 Power Steering Hose Attachment To Power
Steering Pump
19 - 14 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

(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.
CAUTION: Hoses must remain away from exhaust
system, vehicle components and unfriendly sur-
faces causing possible damage to power steering
hoses.
(10) Route power steering pressure hose to pres-
sure port on power steering gear. Install power steer-
ing 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.(11) Install the power steering pressure and return
hose routing clip on hoses (Fig. 8). Install bolt attach-
ing 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 steer-
ing gear tube nut to 34 N´m (25 ft. lbs.).
(13) Install power steering pressure hose in rout-
ing clip on generator shield (Fig. 10).
(14) Lower Vehicle.
(15) Position locating pin on power steering pres-
sure 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.
(17) Start the engine and let run for a few seconds.
Then turn the engine off.
(18) Add fluid if necessary. Repeat the above pro-
cedure 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 vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
(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 compo-
nents.
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 DIS-
CONNECTED 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
Fig. 13 O-ring Installed On Power Steering Hose
Banjo Fitting
Fig. 14 O-ring Installed On Banjo Fitting Bolt
PLSTEERING 19 - 15
REMOVAL AND INSTALLATION (Continued)

steering fluid, drain from return hose and power
steering fluid reservoir, until reservoir is empty.
(3) Remove power steering return hose from rout-
ing clip on generator shield (Fig. 16).
(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 steer-
ing fluid reservoir. If excessive force is used when
trying to remove hose from nipple on power steer-
ing fluid reservoir, nipple can break off of the res-
ervoir.
(6) Remove hose clamp, attaching power steering
return hose to power steering fluid reservoir (Fig.18). Then remove power steering return hose from
power steering fluid 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 try-
ing 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
Fig. 15 Power Steering Return Hose At Steering
Gear
Fig. 16 Power Steering Hose Routing Clip At
Generator Shield
Fig. 17 Tube Clip At Generator Shield
Fig. 18 Power Steering Return Hose At Reservoir
19 - 16 STEERINGPL
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 proce-
dure until the fluid level remains constant after run-
ning 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 vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
(16) After hose is installed, check for leaks at all
hose connections.
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 DIS-
CONNECTED 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 steer-
ing fluid reservoir. If excessive force is used when
trying to remove hose from nipple on power steer-
ing fluid reservoir, nipple can break off of the res-
ervoir.
(1) Remove hose clamp, attaching power steering
fluid supply hose to power steering fluid reservoir(Fig. 19). Then remove power steering fluid supply
hose from power steering fluid 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.
(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 try-
ing to install hose on nipple of power steering fluid
reservoir, nipple can be broken off the reservoir.
Fig. 19 Power Steering Fluid Supply Hose At
Reservoir
Fig. 20 Power Steering Fluid Supply Hose At Power
Steering Pump
PLSTEERING 19 - 17
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 fit-
ting.
(4) Start the engine and let run for a few seconds.
Then turn the engine off.
(5) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning 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 vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
(12) After hose is installed, check for leaks at all
hose connections.
POWER STEERING PUMP (ALL ENGINES)
WARNING: POWER STEERING OIL, ENGINE COM-
PONENTS AND EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED 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).(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.
(5) Raise vehicle on jackstands or centered on a
frame contact type hoist. See hoisting in the Lubrica-
tion 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 over-
head 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
Fig. 21 Power Steering Hose Attachment To Power
Steering Pump
Fig. 22 Power Steering Fluid Supply Hose At Power
Steering Pump
19 - 18 STEERINGPL
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 cool-
ant tube does not need to be removed or the
cooling system drained.
(7) Remove the 2 power steering pump to cast
bracket mounting and adjustment bolts (Fig. 24).
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 steer-
ing 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).(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
Fig. 23 Coolant Tube To Intake Manifold Attachment
Fig. 24 Power Steering Pump Mounting Bolts (Rear)
Fig. 25 Power Steering Pump Front Mounting
Bracket Bolt
Fig. 26 Power Steering Pump And Bracket
PLSTEERING 19 - 19
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 cor-
rect 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.).
(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).(9) Install a new O-ring (Fig. 29) on power steering
fluid pressure hose 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 pres-
sure 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 pro-
cedure 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.
Fig. 27 Setting Power Steering Pump Drive Belt
Tension
Fig. 28 O-Ring Installed On Power Steering Hose
Banjo Fitting
Fig. 29 O-Ring Installed On Banjo Fitting Bolt
19 - 20 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

(23) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
(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 con-
tact 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.
(3) Lower vehicle.
(4) Remove the coolant overflow hose from the
coolant recovery system (CRS) tank (Fig. 31).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.
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.
(6) Remove the power steering fluid return and
supply hose from the power steering fluid reservoir
(Fig. 33).
(7)If vehicle is equipped with the single over-
head cam engine,remove the 3 bolts (Fig. 34)
attaching the power steering fluid reservoir to the
cylinder head.
Fig. 30 Power Steering Return Hose At Steering
Gear
Fig. 31 Overflow Hose Connection At CRS Tank
Fig. 32 CRS Tank Mounting Bolt And Screw
Fig. 33 Power Steering Fluid Hoses At Reservoir
PLSTEERING 19 - 21
REMOVAL AND INSTALLATION (Continued)

(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 .
(9) Remove power steering fluid reservoir from
vehicle.
INSTALL
(1) Install power steering fluid reservoir on cylin-
der 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 sup-
ply hose, on the power steering fluid reservoir fit-
tings (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).(4) Install the coolant overflow hose from the cool-
ant 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 proce-
dure until the fluid level remains constant after run-
ning 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 vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
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.
Fig. 34 Power Steering Fluid Reservoir Hoses And
Mounting
Fig. 35 Power Steering Fluid Reservoir Mounting
19 - 22 STEERINGPL
REMOVAL AND INSTALLATION (Continued)