tra DODGE NEON 2000 Service Repair Manual

(5) Install the wiring harness into the clips on the
side of the air cleaner box.
(6) Install air cleaner element on to throttle body
and push towards the throttle body and past lip in
air cleaner box bottom (Fig. 45).
(7) Install air duct.
(8) Install lid and tighten screws.
AIR CLEANER ELEMENT
REMOVAL
(1) Remove 5 screws from air cleaner element box
lid.(2) Remove lid from air cleaner box.
(3) Pull air cleaner up and out of air cleaner box.
INSTALLATION
(1) Install air cleaner element on to throttle body
and push towards the throttle body and past lip in
air cleaner box bottom (Fig. 46).
(2) Install lid and tighten screws.
ENGINE COOLANT TEMPERATURE SENSOR
The engine coolant temperature sensor threads
into the rear of the cylinder head (Fig. 47).
REMOVAL
(1) With the engine cold, drain coolant until level
drops below cylinder head. Refer to the Cooling Sys-
tem section.
(2) Disconnect coolant sensor electrical connector.
(3) Remove coolant sensor.
INSTALLATION
(1) Install coolant sensor. Tighten sensor to 18
N´m (165 in. lbs.) torque.
(2) Attach electrical connector to sensor.
(3) Fill cooling system. Refer to the Cooling Sys-
tem section.
VEHICLE SPEED SENSOR
The vehicle speed sensor is located in the transmis-
sion extension housing (Fig. 48) or (Fig. 49).
REMOVAL
(1) Disconnect electrical connector from sensor.
(2) Remove the sensor mounting bolt.
Fig. 44 Air Cleaner Box
Fig. 45 Air Cleaner Box Lip
1 ± LIP
Fig. 46 Air Cleaner Element
1 ± LIP
PLFUEL SYSTEM 14 - 47
REMOVAL AND INSTALLATION (Continued)

(3) Lift the sensor out of the transaxle extension
housing. Ensure the O-ring was removed with the
sensor.
INSTALLATION
The speed sensor gear meshes with a gear on the
output shaft.
(1) With O-ring in place, install sensor.
(2) Install mounting bolt.
(3) Connect electrical connector to sensor.
KNOCK SENSOR
The sensors screws into the cylinder block.
REMOVAL
(1) Raise vehicle on hoist and support.
(2) Disconnect electrical connector from knock sen-
sor (Fig. 50).
(3) Use a crows foot socket to remove the knock
sensors.
INSTALLATION
(1) Install knock sensor. Tighten knock sensor to
10 N´m (7 ft. lbs.) torque.Over or under tighten-
ing effects knock sensor performance resulting
in possible improper spark control.
(2) Attach electrical connector to knock sensor.
(3) Lower vehicle.
Fig. 47 Engine Coolant Temperature Sensor
1 ± ENGINE COOLANT TEMPERATURE SENSOR
2 ± CAMSHAFT POSITION SENSOR
Fig. 48 Vehicle Speed Sensor Manual
1 ± TRANSAXLE
2 ± SPEED SENSOR
3 ± SPEED SENSOR RETAINING BOLT
Fig. 49 Vehicle Speed Sensor Automatic
1 ± TRANSAXLE EXTENSION HOUSING
2 ± VEHICLE SPEED SENSOR
Fig. 50 Knock Sensor Location
14 - 48 FUEL SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

SPECIFICATIONS
VECI LABEL
Always use the information found on the Vehicle
Emission Control Information (VECI) label. The
VECI label is located in the engine compartment.
TORQUE
DESCRIPTION TORQUE
Air Cleaner Lid Screws...... 3.9N´m(35in.lbs.)
Crankshaft Position Sensor Mounting Bolts . . 8 N´m
(70 in. lbs.)
Engine Coolant Temperature Sensor...... 18N´m
(165 in. lbs.)
IAC Motor-To-Throttle Body Bolts....... 4.5N´m
(40 in. lbs.)
MAP Sensor............... 4.5N´m(40in.lbs.)
Oxygen Sensor............. 28N´m(20ft.lbs.)
Powertrain Control Module (PCM) Mounting
Screws.................. 4N´m(35in.lbs.)
Throttle Body Mounting Bolts........... 23N´m
(200 in. lbs.)
Throttle Position Sensor Mounting Screws . . 2 N´m
(20 in. lbs.)
Vehicle Speed Sensor Mounting Bolt..... 2.2N´m
(20 in. lbs.)
SPECIAL TOOLS
FUEL
Extractor C±4334
Pressure Gauge Assembly C±4799±B
Fuel Pressure Test Adapter 6539
Spanner Wrench 6856
Metering Orifice
Fuel Line Adapter 1/4
O2S (Oxygen Sensor) Remover/InstallerÐC-4907
PLFUEL SYSTEM 14 - 49

STEERING
TABLE OF CONTENTS
page page
POWER STEERING......................... 1
POWER STEERING PUMP.................. 16STEERING GEAR.......................... 21
STEERING COLUMN....................... 29
POWER STEERING
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
POWER STEERING SYSTEM................1
POWER STEERING FLUID HOSES............2
POWER STEERING FLUID COOLER...........2
POWER STEERING FLUID PRESSURE
SWITCH...............................3
DIAGNOSIS AND TESTING
STEERING SYSTEM DIAGNOSIS CHARTS......4
POWER STEERING SYSTEM FLOW AND
PRESSURE TEST........................9
SERVICE PROCEDURES
POWER STEERING SYSTEM FLUID LEVEL
CHECK...............................11REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS........11
POWER STEERING FLUID PRESSURE HOSE . . . 11
POWER STEERING FLUID RETURN HOSE.....12
POWER STEERING FLUID COOLER..........13
POWER STEERING FLUID PRESSURE
SWITCH..............................14
SPECIFICATIONS
POWER STEERING FASTENER TORQUE
SPECIFICATIONS.......................15
SPECIAL TOOLS
POWER STEERING.......................15
DESCRIPTION AND OPERATION
POWER STEERING SYSTEM
Turning of the steering wheel is converted into lin-
ear travel through the meshing of the helical pinion
teeth with the rack teeth within the steering gear.
Power assist steering is provided by an open-cen-
ter, rotary-type control valve. It is used to direct
power steering fluid from the power steering pump to
either side of the integral steering rack piston. Road
feel is controlled by the diameter of a torsion bar
which initially steers the vehicle. As steering effort
increases as in a turn, the torsion bar twists, causing
relative rotary motion between the rotary valve body
and valve spool. This movement directs fluid behind
the integral rack piston, which in turn builds up
hydraulic pressure and assists in the turning effort.
This vehicle comes with power steering as stan-
dard equipment and it is the only steering systemavailable. The power steering system consists of
these major components:
²POWER STEERING PUMP
²POWER STEERING GEAR
²POWER STEERING FLUID RESERVOIR
(mounted on the pump)
²POWER STEERING FLUID PRESSURE HOSE
²POWER STEERING FLUID RETURN HOSE
²POWER STEERING FLUID COOLER (on some
models)
For information on the first two components, refer
to their respective sections within this service man-
ual group. Information on the third component can
be found in POWER STEERING PUMP. Information
on all other components can be found in this section
of this service manual group.
PLSTEERING 19 - 1

POWER STEERING FLUID HOSES
The power steering fluid hoses connect the compo-
nents of the power steering system. They transfer
fluid from one component to the next.
The power steering fluid pressure hose is a high
pressure hose that connects the power steering pump
to the gear. At both ends of the flexible hose portion
are steel fittings that are pressure crimped to the
flexible hose. A standard tube nut fitting with an
O-ring is used at each end to connect it to either the
power steering pump or the gear.
The power steering fluid return hose is a special
rubber hose that connects the power steering gear or
the power steering fluid cooler on some models, back
to the fluid reservoir mounted on the power steering
pump. The power steering gear has a steel fitting
attached to its outlet port that the return hose is
pushed onto. On vehicles equipped with a power
steering fluid cooler, the return hose attaches to the
cooler outlet tube instead of the steering gear steel
fitting. The hose is secured to either component using
a standard adjustable clamp. The other end of the
power steering fluid return hose attaches to the
power steering fluid reservoir on the power steering
pump using a standard adjustable clamp.
POWER STEERING FLUID COOLER
Some models of this vehicle are equipped with a
cooler for the power steering system fluid (Fig. 1).
The purpose of the cooler is to keep the temperature
of the power steering system fluid from rising to a
level that would affect the performance of the power
steering system.
The power steering fluid cooler is located at the
front of the front suspension crossmember. It is
mounted to the crossmember top surface using 2 fas-
teners.The cooler is placed in series with the power steer-
ing fluid return hose, between the steering gear fluid
outlet port and the fluid return hose leading to the
power steering fluid reservoir. The power steering
gear has a steel fitting attached to its outlet port
that a short hose leading to the cooler is pushed onto.
This hose is secured to both the steering gear outlet
fitting and the cooler using standard adjustable
clamps. The cooler is secured to the power steering
fluid return hose using a standard adjustable clamp.
The cooler used on this vehicle is referred to as a
fluid-to-air type cooler. This means that the air flow
across the tubes of the cooler is used to extract the
heat from the cooler which it has absorbed from the
power steering fluid flowing through it. Utilizing a
small air dam mounted to its base to redirect air
across its coils, the cooler lowers the temperature of
the power steering fluid prior to it entering the
power steering fluid reservoir where it is resupplied
to the power steering pump.
Fig. 1 Power Steering Fluid Cooler
1 ± POWER STEERING FLUID COOLER
2 ± TRANSAXLE
3 ± CLAMP
4 ± AIR DAM
5 ± CROSSMEMBER
19 - 2 STEERINGPL
DESCRIPTION AND OPERATION (Continued)

POWER STEERING FLUID PRESSURE SWITCH
A power steering pressure switch is used to
improve the vehicle's idle quality. The pressure
switch improves vehicle idle quality by causing a
readjustment of the engine idle speed as necessary
when increased fluid pressure is sensed in the power
steering system.
The pressure switch functions by signaling the
powertrain control module that an increase in pres-
sure of the power steering system is putting addi-
tional load on the engine. This type of condition
exists when the front tires of the vehicle are turned
while the vehicle is stationary and the engine is at
idle speed. When the powertrain control module
receives the signal from the power steering pressure
switch, it directs the engine to increase its idle speed.
This increase in engine idle speed compensates for
the additional load, thus maintaining the required
engine idle speed and idle quality.The power steering pressure switch is mounted
directly to the power steering gear (Fig. 2).
Fig. 2 Switch Location
1 ± WIRING HARNESS CONNECTOR
2 ± POWER STEERING GEAR
3 ± POWER STEERING FLUID PRESSURE SWITCH
4 ± REAR OF FRONT SUSPENSION CROSSMEMBER
PLSTEERING 19 - 3
DESCRIPTION AND OPERATION (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
WHINE OR GROWL (POWER
STEERING PUMP)**1. Low fluid level. 1. Fill power steering fluid reservoir
to proper level and check for leaks.
2. Power steering hose touching
vehicle body or frame.2. Adjust hose to proper position by
loosening, repositioning, and
tightening fitting to specified torque.
Do not bend tubing. Replace hose if
damaged.
3. Extreme wear of power steering
pump internal components.3. Replace power steering pump and
flush system as necessary.
SUCKING AIR SOUND 1. Loose clamp on power steering
fluid return hose.1. Tighten or replace hose clamp.
2. Missing O-Ring on power steering
hose connection.2. Inspect connection and replace
O-Ring as required.
3. Low power steering fluid level. 3. Fill power steering fluid reservoir
to proper level and check for leaks.
4. Air leak between power steering
fluid reservoir and power steering
pump.4. Replace power steering pump
(with reservoir).
SQUEAK OR RUBBING SOUND 1. Steering column shroud rubbing. 1. Realign shrouds as necessary.
2. Steering column shaft rubbing. 2. Move or realign item rubbing
shaft.
3. Steering column shaft dry-rubbing
seal at dash panel.3. Lubricate contact surface.
4. Steering gear internally noisy. 4. Replace steering gear.
SCRUBBING OR KNOCKING
NOISE.1. Incorrect tire or wheel size. 1. Replace incorrect size tire or
wheel with size used as original
equipment.
2. Interference between steering
gear and other vehicle components.2. Check for bent or misaligned
components and correct as
necessary.
3. Steering gear internal stops worn
excessively.3. Replace steering gear.
NOTE: * There is some noise in all power steering
systems. One of the most common is a hissing
sound evident when turning the steering wheel
when at a standstill or when parking and the steer-
ing wheel is at the end of its travel. Hiss is a very
high frequency noise similar to that experienced
while slowly closing a water tap. The noise is
present in every valve and results when high veloc-
ity fluid passes valve orifice edges. There is no
relationship between this noise and the perfor-
mance of the steering system.NOTE: ** Power steering pump growl results from
the development of high pressure fluid flow. Nor-
mally this noise level should not be high enough to
be objectionable.
PLSTEERING 19 - 5
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
6. Damaged, mis-positioned or
un-lubricated steering column
coupler to dash seal.**6. Replace, reposition, or lubricate dash
seal.
7. Binding upper strut bearing. 7. Disassemble strut assembly. Correct
binding condition in strut bearing or replace
bearing.
8. Tight shaft bearing in steering
column.8. Replace the steering column.
9. Excessive friction in steering
column coupling.9. Replace steering column coupling.
10. Excessive friction in power
steering gear.10. Replace power steering gear.
EXCESSIVE STEERING
WHEEL KICKBACK OR
TOO MUCH STEERING
WHEEL FREE PLAY.1. Air in the fluid of the power
steering system.1. Bleed air from system following the the
power steering pump initial operation
service procedure.*
2. Power steering gear loose on front
suspension crossmember.2. Inspect power steering gear mounting
bolts. Replace as necessary. Tighten to the
specified torque.
3. Steering column coupling worn,
broken or loose.3. Replace steering column coupling.
4. Free play in steering column. 4. Check all components of the steering
system and repair or replace as required.
5. Worn control arm ball joints. 5. Replace ball joint or control arm as
required.
6. Loose steering knuckle to ball joint
stud pinch bolt.6. Inspect pinch bolts, replace as
necessary, and tighten to specified torque.
7. Front wheel bearings loose or
worn.7. Replace wheel bearing or knuckle as
necessary.
8. Loose outer tie rod ends. 8. Replace outer tie rod ends that have
excessive free play.
9. Loose inner tie rod ends. 9. Replace power steering gear.
10 Defective steering gear rotary
valve.10. Replace power steering gear.
NOTE: * Steering shudder can be expected in new
vehicles and vehicles with recent steering system
repairs. Shudder should dissipate after the vehicle
has been driven several weeks.
NOTE: ** To evaluate this condition, it may be nec-
essary to disconnect the coupling at the base of the
steering column. Turn the steering wheel and feel or
listen for internal rubbing in steering column. To
avoid damaging the column clockspring, note thefollowing. Before disconnecting coupling, place
tires in the straight-ahead position and center steer-
ing wheel. Once disconnected, DO NOT rotate
steering wheel more than one revolution in either
direction and place steering wheel in original loca-
tion before reconnecting coupling. If this position is
lost, the steering column clockspring must be
recentered following the procedure found within the
procedure for steering column installation in the
steering column section.
19 - 8 STEERINGPL
DIAGNOSIS AND TESTING (Continued)

CAUTION: Do not force the pump to operate
against the stops for more than 5 seconds at a time
as pump damage may result.
(6) Completely open the valve on the Power Steer-
ing Analyzer flow meter. Turn the steering wheel to
the extreme left until the stop in the steering gear is
met, then turn the steering wheel to the right until
the right stop is met. Record the highest indicated
pressure at each position. Compare the recorded
readings to the specifications. If the highest output
pressure reading against one stop is within 50 psi of
the highest reading at the other stop, the steering
gear is leaking internally and must be replaced.
If the power steering gear requires replacement,
refer to the section POWER STEERING GEAR
within this group for the removal and installation
procedure.
SERVICE PROCEDURES
POWER STEERING SYSTEM FLUID LEVEL
CHECK
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
Before opening power steering system, wipe the
reservoir filler cap free of dirt and debris. Remove
the cap and check the fluid level on its dipstick.
When the fluid is at normal ambient temperature,
approximately 21ÉC to 27ÉC (70ÉF to 80ÉF), the dip-
stick level should indicateCOLD. Do not overfill the
power steering system. In all power steering systems,
use only Mopar Power Steering Fluid, or its equiva-
lent.
NOTE: Do not use any type of automatic transmis-
sion fluid in the power steering system.
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS
WARNING: POWER STEERING FLUID, 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.WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
CAUTION: When the system is open, cap all open
ends of the hoses, power steering pump fittings or
power steering gear ports to prevent entry of for-
eign material into the components.
NOTE: Do not use any type of automatic transmis-
sion fluid in the power steering system.
POWER STEERING FLUID PRESSURE HOSE
NOTE: Before proceeding with this removal and
installation procedure, review SERVICE WARNINGS
AND CAUTIONS at the beginning of REMOVAL AND
INSTALLATION in this section.
REMOVAL
(1) Siphon as much fluid as possible from the
power steering fluid reservoir.
(2) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group in this
service manual for the correct lifting procedure.
(3) Back out the tube nut securing the power
steering fluid pressure hose to the gear (Fig. 6).
Fig. 6 Power Steering Hoses At Gear
1 ± PRESSURE HOSE TUBE NUT
2 ± RETURN HOSE
3 ± POWER STEERING GEAR
4 ± FRONT SUSPENSION CROSSMEMBER
PLSTEERING 19 - 11
DIAGNOSIS AND TESTING (Continued)

(3) Install the hose clamp on the power steering
cooler fluid hose past the bead formed into the steel
fitting and secure in place.
(4) Install the two screws attaching the cooler to
the front suspension crossmember. Tighten the cooler
attaching screws to a torque of 10 N´m (90 in. lbs.).
(5) Install the power steering fluid return hose on
the power steering fluid cooler tube. Install the hose
clamp on the power steering return hose securing it
to the power steering cooler. Be sure the hose clamp
is installed on the return hose past the bead on the
end of the cooler tube.
(6) Lower the vehicle.
(7) Perform the POWER STEERING PUMP INI-
TIAL OPERATION service procedure which can be
found in the POWER STEERING PUMP section of
this group to properly fill and bleed the power steer-
ing system.
(8) Check for leaks at all connections.
POWER STEERING FLUID PRESSURE SWITCH
NOTE: Before proceeding with this removal and
installation procedure, review SERVICE WARNINGS
AND CAUTIONS at the beginning of REMOVAL AND
INSTALLATION in this section.
REMOVAL
(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 the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group in this
service manual for the correct lifting procedure.
(3) Locate the power steering fluid pressure switch
on the back side of the power steering gear (Fig. 9).
(4) Remove the vehicle wiring harness connector
from the power steering fluid pressure switch.
NOTE: When removing and installing the power
steering pressure switch, use a 7/8 inch deep well
socket. The deep well socket will prevent damage
to the plastic electrical connector area of the power
steering fluid pressure switch.
(5) Unscrew and remove the power steering fluid
pressure switch from the power steering gear.
INSTALLATION
(1) By hand, screw the power steering pressure
switch into the power steering gear until it is fully
seated (Fig. 9). Tighten the power steering pressure
switch to a maximum torque of 8 N´m (70 in. lbs.).
Over-torquing will result in stripping the threads out
of the power steering pressure switch port in the
steering gear.
(2) Install the vehicle wiring harness connector. Be
sure the latch on the wiring harness connector is
fully engaged with the locking tab on the power
steering pressure switch.
(3) Lower the vehicle.
(4) Fill the power steering fluid reservoir to the
correct fluid level. Use only MopartPower Steering
Fluid, or equivalent.
(5) Connect the negative cable to the negative post
of the battery.
Fig. 8 Power Steering Fluid Cooler
1 ± POWER STEERING FLUID COOLER
2 ± TRANSAXLE
3 ± CLAMP
4 ± AIR DAM
5 ± CROSSMEMBER
Fig. 9 Switch Location
1 ± WIRING HARNESS CONNECTOR
2 ± POWER STEERING GEAR
3 ± POWER STEERING FLUID PRESSURE SWITCH
4 ± REAR OF FRONT SUSPENSION CROSSMEMBER
19 - 14 STEERINGPL
REMOVAL AND INSTALLATION (Continued)