warning light DODGE NEON 1999 Service Owner's Guide

8W-90 CONNECTOR/GROUND LOCATIONS
DESCRIPTION AND OPERATION
INTRODUCTION
This section provides illustrations identifying com-
ponent and connector locations in the vehicle. A con-
nector index is provided. Use the wiring diagrams ineach section for connector number identification.
Refer to the index for the proper figure number.CONNECTOR/GROUND LOCATIONS(LHD)
For items not shown in this section a N/S is placed
in the Fig. column.
Connector
Name/NumberColor Location Fig.
A/C Compressor
ClutchBK Top of A/C
Compressor9
A/C Cycling
SwitchBK Center of HVAC
HousingN/S
A/C-Heater
Blower MotorBK RT Side of
HVAC HousingN/S
A/C-Heater
ControlBK Rear of HVAC
Control15
A/C Hi-Pressure
SwitchGY Top of A/C
Compressor9
A/C Low
Pressure SwitchBK RT Rear Cowl
Panel5
Airbag Control
ModuleYL Rear of
Gearshift13
Ash Receiver
LampBK At Lamp N/S
Back-Up Lamp
SwitchGY Top of
Transmission4
Battery BK Left Front
Engine
Compartment7
Battery Temp
SensorBK Bottom of
Battery Tray7
Blower Motor
Resistor BlockNAT RT Side Cowl
Panel10
Brake Warning
Lamp SwitchBK LT Frame Rail 6
C101 BR Top Center of
I.P.15
C102 BK Top Center of
I.P.15
C103 BL Top Center of
I.P.15
C105 BK LT Kick Panel N/S
Connector
Name/NumberColor Location Fig.
C108 BK Rear of ABS
Hydraulic Unit3
C160 LT/GY Near PDC 6
C161 BK Near PDC 6
C170 NAT Top Center of
I.P.N/S
C205 BL RT Kick Panel 16
C206 BL Top Right of I.P. 15
C225 RD Top of I.P. 15
C230 GY LT Side of I.P. 14
C231 BL Left Kick Panel 14
C242 BK Behind Center
StackN/S
C301 GY RT B-Pillar 19
C303 GY LT B-Pillar 19
C309 BK LT Rear Wheel
Well22
C340 BK Left Rear
Quarter PanelN/S
C341 BK Right Rear
Quarter PanelN/S
Camshaft
Position SensorBK LT Rear of Cyl
Head8
CHMSL BK Rear of Lamp 22
Cigar Lighter/
Power OutletBottom Center
Stack14
Clockspring NAT Rear of Steering
Wheel12
Clutch Pedal
Position SwitchBK Top of Clutch
Pedal2
Controller
Anti-Lock BrakeBK Left Rear
Engine
Compartment3
Crankshaft
Position SensorBK Rear of Engine 8
Data Link
ConnectorBK LT Side of
Steering Column14
PL8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1

CONNECTOR/GROUND LOCATIONS (RHD)
For items not shown in this section a N/S is placed
in the Fig. column.
Connector
Name/NumberColor Location Fig.
A/C
Compressor
ClutchBK Top of A/C
Compressor8
A/C Cycling
SwitchBK Center of
HVAC HousingN/S
A/C-Heater
Blower MotorBK Right Side of
HVAC HousingN/S
A/C-Heater
ControlBK Rear of HVAC
Control13
A/C Hi-Pressure
SwitchGY Top of A/C
Compressor8
A/C Low
Pressure SwitchBK Left Rear Cowl
PanelN/S
Airbag Control
ModuleYL Rear of
Gearshift11
Ash Receiver
LampBK At Lamp N/S
Back-Up Lamp
SwitchGY Top of
Transmission3
Battery Left Front of
Engine
Compartment6
Battery Temp
SensorBK Bottom of
Battery Tray6
Blower Motor
Resistor BlockNAT Left Side Cowl
PanelN/S
Brake Warning
Lamp SwitchBK Right Frame
RailN/S
C101 BR Top of I.P. 13
C102 BK Top of I.P. 13
C103 BL Top of I.P. 13
C105 BK Right Kick
PanelN/S
C108 BK Left Lower
CowlN/S
C160 LT/GY Left Fender
Side Shield5
C161 BK Left Fender
Side Shield5Connector
Name/NumberColor Location Fig.
C170 NAT Top Center of
I.P.N/S
C205 BL Right Kick
PanelN/S
C206 BL Top Left of I.P. 13
C225 RD Left Kick Panel 9
C230 GY Right Kick
Panel14
C231 BL Left Side of I.P. 13
C301 GY Right B-Pillar 15
C303 GY Left B-Pillar 15
C309 BK Left Rear
Wheel Well18
C340 BK Left Rear
Quarter Panel20
C341 BK Right Rear
Quarter Panel20
Camshaft
Position SensorBK Left Side of
Engine7
CHMSL BK Rear of Lamp 18
Cigar Lighter/
Power OutletBottom Center
of Stack13
Clockspring NAT Rear of
Steering Wheel10
Clutch Pedal
Position SwitchBK Top of Clutch
Pedal2
Controller
Anti-Lock BrakeBK Left Rear of
Engine
CompartmentN/S
Crankshaft
Position SensorBK Rear of Engine 7
Data Link
ConnectorBK Left Side of
Steering
ColumnN/S
Dome Lamp BK LT C-Pillar 20
Downstream
Heated Oxygen
SensorBK Rear of
Catalytic
ConverterN/S
Driver Side
Airbag SquibYL Rear of
Clockspring12
Duty Cycle
Evap/Purge
SolenoidGY RT Strut Tower 10
PL8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 23
DESCRIPTION AND OPERATION (Continued)

cause of low compression unless some malfunc-
tion is present.
(11) Clean or replace spark plugs as necessary
and adjust gap as specified in Group 8, Electrical.
Tighten to specifications.
(12) Test resistance of spark plug cables. Refer to
Group 8, Electrical Ignition System Secondary Cir-
cuit Inspection.
(13) Test coil output voltage, primary and second-
ary resistance. Replace parts as necessary. Refer to
Group 8, Electrical Ignition System.
(14) Check fuel pump pressure at idle and differ-
ent RPM ranges. Refer to Group 14, Fuel System for
Specifications.
(15) The air filter elements should be replaced as
specified in Group 0, Lubrication and Maintenance,.
(16) Inspect crankcase ventilation system as out
lined in Group 0, Lubrication and Maintenance. For
emission controls see Group 25, Emission Controls
for service procedures.
(17) Inspect and adjust accessory belt drives refer-
ring to Group 7, Cooling System, Accessory Drive
Belts for proper adjustments.
(18) Road test vehicle as a final test.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1 379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may
cause aerated oil to enter the adjusters and cause
them to be spongy.
(2) Insufficient running time after rebuilding cylin-
der head. Low speed running up to 1 hour may be
required.
(3) During this time, turn engine off and let set for
a few minutes before restarting. Repeat this several
times after engine has reached normal operating
temperature.
(4) Low oil pressure.
(5) The oil restrictor pressed into the vertical oil
passage to the cylinder head is plugged with debris.
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Faulty lash adjuster.
a. Check lash adjusters for sponginess while
installed in cylinder head. Depress part of rocker
arm over adjuster. Normal adjusters should feel very
firm. Spongy adjusters can be bottomed out easily.
b. Remove suspected rocker arms (sohc) or lash
adjuster (dohc) and replace.
INSPECTION (ENGINE OIL LEAKS IN GENERAL)
Begin with a through visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
9 - 8 ENGINEPL
DIAGNOSIS AND TESTING (Continued)

WARNING: THE FUEL RESERVOIR OF THE FUEL
PUMP MODULE DOES NOT EMPTY OUT WHEN THE
TANK IS DRAINED. THE FUEL IN THE RESERVOIR
WILL SPILL OUT WHEN THE MODULE IS
REMOVED.
(2) Disconnect fuel line from fuel pump module by
depressing quick connect retainers with thumb and
fore finger.
(3) Slide fuel pump module electrical connecter
lock to unlock.
(4) Disconnect the electrical connection from the
fuel pump module, by pushing down on connector
retainer and pulling connector off of module.
(5) Use a transmission jack to support the fuel
tank. remove bolts from fuel tank straps.
(6) Lower tank slightly.
(7) Use Special Tool 6856 to remove fuel pump
module locknut (Fig. 17).
(8) Remove fuel pump and O-ring seal from tank.
Discard old seal.
INSTALLATION
(1) Wipe seal area of tank clean and place a new
seal in position in the tank opening.
(2) Position fuel pump in the tank. Make sure the
aligment tab on the underside of the fuel pump mod-
ule flange sits in the notch on the fuel tank.
(3)
Position the locknut over the fuel pump module.
(4) Tighten the locknut using Special Tool 6856 to
55 N´m (40.5 ft. lbs.) (Fig. 17).
CAUTION: Over tightening the pump lock ring may
result in a leak.
(5) Fill fuel tank. Check for leaks.
FUEL FILTER / PRESSURE REGULATOR
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE, EVEN WITH ENGINE OFF. BEFORE
SERVICING THE FUEL FILTER/FUEL PRESSURE REG-
ULATOR, THE FUEL SYSTEM PRESSURE MUST BE
RELEASED.
(1) Refer to Fuel System Pressure Release in the
Fuel Delivery System section of this group.
The fuel filter/fuel pressure regulator is located on
the top of fuel pump module. Fuel pump module
removal is not necessary.
(2) Raise vehicle on hoist.
(3) Disconnect fuel supply line at the Filter/Regu-
lator nipple (refer to Quick Connect Fittings in this
section).
(4) Depress locking spring tab on side of Fuel/Reg-
ulator (Fig. 18) and rotate 90É counter-clockwise and
pull out.
NOTE: Make sure that the upper and lower O-rings
are on the Filter/Regulator assembly.
INSTALLATION
Lightly lubricate the O-rings with engine oil.
(1) Insert Filter/Regulator into the opening in the
fuel pump module, align the two hold down tabs with
the flange.
(2) While applying downward pressure, rotate the
Filter/Regulator clockwise until the the spring tab
engages the locating slot (Fig. 19).
(3) Connect the fuel line to the Filter/Regulator.
(4) Lower vehicle from hoist.
Fig. 16 Fuel Pump Module Removal
Fig. 17 Fuel Tank Locknut
14 - 12 FUEL SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

(5) Remove fuel rail mounting screws.
(6) Lift rail off of intake manifold. Cover the fuel
injector openings in the intake manifold.
(7) Remove fuel injector retainer (Fig. 28).
(8) Pull injector out of fuel rail. Replace fuel injec-
tor O-rings (Fig. 29).
INSTALLATION
(1) Apply a light coating of clean engine oil to the
upper O-ring.(2) Install injector in cup on fuel rail.
(3) Install retaining clip.
(4) Apply a light coating of clean engine oil to the
O-ring on the nozzle end of each injector.
(5) Insert fuel injector nozzles into openings in
intake manifold. Seat the injectors in place. Tighten
fuel rail mounting screws to 22.5 N´m63 N´m
(200630 in. lbs.).
(6) Attach electrical connectors to fuel injectors.
(7) Connect fuel supply tube to fuel rail. Refer to
Quick Connect Fittings in the Fuel Delivery Section
of this Group.
FUEL TANK
REMOVAL
(1) Perform fuel system pressure release.
(2) Drain fuel tank. Refer to Draining Fuel Tank
in this section (Fig. 30).
(3) Raise vehicle on hoist.
WARNING: WRAP SHOP TOWELS AROUND
HOSES TO CATCH ANY GASOLINE SPILLAGE.
(4) Disconnect fuel pump module electrical connec-
tor (Fig. 31).
(5) Disconnect the fuel tube from Fuel Filter/Reg-
ulator. Refer to Quick Connect Fittings in the Fuel
Delivery section of this group.
(6) Support tank with transmission jack. Loosen
tank mounting straps and lower tank slightly.
(7) Disconnect fuel filler tube and filler vent tube
from filler hose at fuel tank (Fig. 32).
(8) Disconnect fuel filler vapor relief tube from tee
connecting it to the tank vapor relief tube and EVAP
canister tube.
(9) Disconnect vapor line from Evap canister tube.
(10) Remove tank mounting straps and lower tank.Fig. 27 Fuel Rail and Injectors
Fig. 28 Fuel Injector Retainer
Fig. 29 Fuel Injector O-Rings
Fig. 30 Fuel Tank
PLFUEL SYSTEM 14 - 15
REMOVAL AND INSTALLATION (Continued)

should be in the range of 345-552 kPa (50-80 psi).
The flow meter should read between 1.3 and 1.4
GPM
CAUTION: The following test procedure involves
testing power steering pump maximum pressure
output and flow control valve operation. Do not
leave valve closed for more than 5 seconds as the
pump could be damaged.
(8) Close valve fully three times and record high-
est pressure indicated each time.All three read-
ings must be above specifications and within
345 kPa (50 psi) of each other.
NOTE: Power steering pump maximum relief pres-
sure is 8240 to 8920 kPa (1195 to 1293 psi.).
²If power steering pump pressures above specifi-
cations but not within 345 kPa (50 psi) of each other,
then replace power steering pump.
²If pressures within 345 kPa (50 psi) of each
other but below specifications, then replace power
steering pump.
CAUTION: Do not force the pump to operate
against the stops for more than 5 seconds at a time
because, pump damage will result.
(9) Open test valve. Turn steering wheel to the
extreme left and right positions until against the
stops, recording the highest indicated pressure at
each position. Compare pressure gauge readings to
power steering pump specifications. If highest output
pressures are not the same against either stop, the
steering gear is leaking internally and must be
replaced.
SERVICE PROCEDURES
POWER STEERING SYSTEM FLUID LEVEL CHECK
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH ENGINE OFF TO PREVENT INJURY FROM
MOVING PARTS. DO NOT USE AUTOMATIC TRANS-
MISSION FLUID IN THE POWER STEERING SYS-
TEM. DO NOT OVERFILL THE POWER STEERING
SYSTEM.
Wipe reservoir filler cap free of dirt. Then check
fluid level. The dipstick should indicate COLD when
fluid is at normal ambient temperature, approxi-
mately 21ÉC to 27ÉC (70ÉF to 80ÉF). In all pumps add
fluid as necessary, use onlyMopar Power Steering
Fluid, or equivalent. DO NOT USE ANY TYPE
OF AUTOMATIC TRANSMISSION FLUID.
POWER STEERING PUMP INITIAL OPERATION
CAUTION: The fluid level should be checked with
engine off to prevent injury from moving compo-
nents. Use only MoparTPower Steering Fluid. Do
not use automatic transmission fluid. Do not over-
fill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateFULL COLDwhen the
fluid is at normal temperature of approximately 21ÉC
to 27ÉC (70ÉF to 80ÉF).
(1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(2) Start the engine and let run for a few seconds.
Then turn the engine off.
(3) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine.
(4) Raise the front wheels off the ground.
(5) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
stops.
(6) Add power steering fluid if necessary.
(7) Lower the vehicle and turn the steering wheel
slowly from lock to lock.
(8) Stop the engine. Check the fluid level and refill
as required.
(9) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
POWER STEERING PUMP FLOW CONTROL VALVE
SEAL
The power steering pump does not require removal
from the engine for removal and replacement of the
flow control valve fitting O-Ring.
REMOVE
(1) Remove the power steering fluid pressure hose
from the power steering pump pressure fitting (Fig.
4).
(2) Remove the flow control valve fitting from the
power steering pump housing (Fig. 5).Prevent flow
control valve and spring from sliding out of
housing bore.
(3) Remove and discard O-ring seal from fitting.
INSTALL
(1) If necessary, clean and install flow control
valve and spring in pump housing bore.
(2) Install new O-ring seal on fitting.
(3) Install fitting in pump housing and tighten to
75 N´m (55 ft. lbs.)
(4) Install power steering fluid pressure hose on
flow control valve fitting.
PLSTEERING 19 - 11
DIAGNOSIS AND TESTING (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)

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)

CAUTION: Do not install steering wheel onto shaft
of steering column assembly by driving it onto the
shaft. Pull steering wheel down onto steering col-
umn shaft using ONLY the steering wheel retaining
nut.
(13) Feed clock spring wiring leads through hole in
steering wheel (Fig. 20). Position steering wheel on
shaft of steering column assembly, making sure to fit
flats on hub of steering wheel with formations on
inside of clockspring.
(14) Install steering wheel to steering column
shaft retaining nut and tighten until steering wheel
is fully installed on shaft. The tighten steering wheel
retaining nut to a torque of 61 N´m (45 ft. lbs.).
(15) Connect the clockspring electrical leads to
components such as horn switches and speed control
switches located in the steering wheel (Fig. 11).
(16) Install air bag electrical lead from clock
spring, into connector on back of air bag module (Fig.
10).Be sure electrical connector from clock-
spring is securely latched into air bag module
connector.
CAUTION: The fasteners, screws, and bolts, origi-
nally used for the air bag components are specifi-
cally designed for the air bag system. They must
never be replaced with any substitutes. Anytime a
new fastener is needed, replace only with correct
fasteners provided in service packages or fasteners
listed in the parts book.
(17) Install air bag module into center of steering
wheel. Align air bag module mounting holes with bolt
holes in steering wheel. Installonly the 2 original
or correct replacementair bag module attachingbolts (Fig. 9). Torque the 2 air bag module attaching
bolts to 10 N´m (90 in. lbs.).
(18) Install key lock cylinder into lock housing.
Key lock cylinder is installed by positioning key cyl-
inder in the run position so retaining tab can be
depressed and the pushing key cylinder into lock hos-
ing until retaining tab locks into key lock cylinder.
(19) Reconnect ground cable to Negative post of
the battery.When reconnecting battery on a
vehicle that has had the air bag module
removed, the following procedure should be
used.
²Remove forward console or cover as necessary.
²Connect DRB II to ASDM diagnostic 6-way con-
nector, located at right side of the ASDM module.
²Turn ignition key to ON position. Exit vehicle
with the DRB II. Install the latest version of the
proper diagnostic cartridge into the DRB II.
²Ensuring that their are no occupants in the
vehicle, connect negative cable to negative post of the
battery.
²Using the DRB II read and record active fault
codes. Also read and record any stored fault codes.
Refer to the Passive Restraint Diagnostic Test Man-
ual if any faults are found.
²Erase stored faults if there are no active fault
codes. If problems remain, fault codes will not erase.
²From the passenger side of the vehicle, turn
ignition key to OFF and then ON observing instru-
ment cluster air bag lamp. It should go on for six to
eight seconds, then go out. This will indicate that the
air bag system is functioning normally.
(20)If air bag warning lamp fails to light,
blinks on and off or goes on and stays on, there
is an air bag system malfunction.Refer to the
Passive Restraint Diagnostic Test Manual to diag-
nose the system malfunction.
(21) Test the operation of the horn, lights and any
other functions that are steering column operated. If
applicable reset the radio and the clock.
(22) Road test vehicle to ensure proper operation
of the steering system and the speed control system.
SPECIFICATIONS
STEERING COLUMN FASTENER TORQUE
SPECIFICATIONS
DESCRIPTION TORQUE
Steering Wheel
Retaining Nut...............61N´m(45ft.lbs.)
Steering Column Assembly
Upper And Lower Mounting Bracket
Attaching Nuts...........17N´m(150 in. lbs.)
Fig. 20 Steering Wheel Installation
19 - 42 STEERINGPL
REMOVAL AND INSTALLATION (Continued)