power steering DODGE NEON 2000 Service Manual PDF

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)

DIAGNOSIS AND TESTING
STEERING SYSTEM DIAGNOSIS CHARTS
POWER STEERING NOISE
CONDITION POSSIBLE CAUSES CORRECTION
OBJECTIONABLE HISS OR
WHISTLE*1. Damaged or mispositioned
steering column shaft/coupling dash
panel seal.1. Reposition or replace steering
column shaft/coupling dash panel
seal.
2. Noisy valve in power steering
gear.2. Replace power steering gear.
RATTLE OR CLUNK 1. Power steering gear loose on
front suspension crossmember.1. Inspect power steering gear
mounting bolts. Replace as
necessary. Tighten to the specified
torque.
2. Front suspension crossmember
mounting fasteners loose at frame.2. Tighten the front suspension
crossmember mounting fasteners to
the specified torque.
3. Loose tie rod (outer or inner). 3. Check tie rod pivot points for
wear. Replace worn/loose parts as
required.
4. Loose lower control arm mounting
bolts at front suspension
crossmember.4. Tighten control arm mounting
bolts to the specified torques.
5. Loose strut assembly mounting
fasteners at strut tower.5. Tighten strut assembly fasteners
to the specified torques.
6. Power steering fluid pressure
hose touching the body of the
vehicle.6. Adjust hose to proper position by
loosening, repositioning, and
tightening fitting to specified torque.
Do not bend tubing.
7. Internal power steering gear
noise.7. Replace power steering gear.
8. Damaged front suspension
crossmember.8. Replace front suspension
crossmember.
CHIRP OR SQUEAL (POWER
STEERING PUMP)1. Loose power steering pump drive
belt.1. Check and replace automatic belt
tensioner as necessary. Replace belt
if worn or glazed.
19 - 4 STEERINGPL

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)

STEERING WHEEL FEEL
CONDITION POSSIBLE CAUSES CORRECTION
STEERING WHEEL/
COLUMN CLICKING,
CLUNKING OR RATTLING.1. Steering column preload is not set
properly.1. Loosen steering column coupling pinch
bolt to reset steering column preload.
Replace pinch bolt and torque to
specifications.
2. Loose steering coupling pinch
bolt.2. Replace pinch bolt and torque to
specifications.
3. Steering column bearings. 3. Replace steering column.
STEERING WHEEL HAS
FORE AND AFT
LOOSENESS.1. Steering wheel retaining nut not
properly tightened and torqued.1. Tighten the steering wheel retaining nut
to its specified torque.
2. Steering column preload is not set
properly.2. Loosen steering column coupling pinch
bolt to reset steering column preload.
Replace pinch bolt and torque to
specifications.
3. Steering column lower bearing
spring retainer slipped on steering
column shaft.3. Replace steering column.
STEERING WHEEL OR
DASH VIBRATES DURING
LOW SPEED OR
STANDSTILL STEERING
MANEUVERS.1. Air in the fluid of the power
steering system.1. Bleed air from system following the
power steering pump initial operation
service procedure.*
2. Tires not properly inflated. 2. Inflate tires to the specified pressure.
3. Excessive engine vibration. 3. Ensure that the engine is running
properly.
4. Loose tie rod end jam nut. 4. Tighten the inner to outer tie rod jam nut
to the specified torque.
5. Overcharged air conditioning
system.5. Check air conditioning pump head
pressure and correct as necessary.
STEERING CATCHES,
STICKS IN CERTAIN
POSITIONS OR IS
DIFFICULT TO TURN.1. Low power steering fluid level. 1. Fill power steering fluid reservoir to
specified level and check for leaks.
2. Tires not inflated to specified
pressure.2. Inflate tires to the specified pressure.
3. Lack of lubrication in front
suspension control arm ball joints.3. Lubricate ball joints if ball joints are not a
lubricated for life type ball joint. If ball joint
is a lubricated for life ball joint, replace ball
joint or control arm.
4. Lack of lubrication in steering gear
outer tie rod ends.4. Lubricate tie rod ends if they are not a
lubricated for life type. If tie rod end is a
lubricated for life type, replace tie rod end.
5. Loose power steering pump drive
belt.5. Check and replace automatic belt
tensioner as necessary. If drive belt is worn
or glazed, replace belt.
19 - 6 STEERINGPL
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
6. Faulty power steering pump flow
control (Follow Power Steering
System Flow and Pressure Test
procedure).6. Replace power steering pump.
7. Excessive friction in steering
column or intermediate shaft.7. Isolate and correct condition.
8. Binding upper strut bearing. 8. Disassemble strut assembly. Correct
binding condition in strut bearing or replace
bearing.
9. Excessive friction in power
steering gear.9. Replace power steering gear.
STIFF, HARD TO TURN,
SURGE, MOMENTARY
INCREASE IN EFFORT
WHEN TURNING.1. Tires not properly inflated. 1. Inflate tires to specified pressure.
2. Low power steering fluid level. 2. Add power steering fluid as required to
power steering fluid reservoir to obtain
proper level. Check for leaks.
3. Loose power steering pump drive
belt.3. Check and replace automatic belt
tensioner as necessary. If drive belt is worn
or glazed, replace belt.
4. Lack of lubrication in control arm
ball joints.4. Lubricate ball joints if ball joints are not a
lubricated for life type ball joint. If ball joint
is a lubricated for life ball joint, replace ball
joint or control arm.
5. Low power steering pump
pressure (Follow Power Steering
System Flow and Pressure Test
procedure).5. Replace the power steering pump as
necessary.
6. High internal leak in power
steering gear (Follow Power Steering
System Flow and Pressure Test
procedure).6. Replace power steering gear.
STEERING WHEEL DOES
NOT RETURN TO
CENTER POSITION.1. Tires not inflated properly. 1. Inflate tires to specified pressure.
2. Improper front wheel alignment. 2. Check and adjust wheel alignment as
necessary.
3. Lack of lubrication in front
suspension control arm ball joints.3. Lubricate ball joints if ball joints are not a
lubricated for life type of ball joint. If ball
joint is a lubricated for life ball joint, replace
ball joint or control arm.
4. Steering column coupling joints
misaligned.4. Realign steering column coupling joints.
5. Steering wheel rubbing.** 5. Adjust steering column shrouds to
eliminate rubbing condition.
PLSTEERING 19 - 7
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)

POWER STEERING FLUID
CONDITION POSSIBLE CAUSES CORRECTION
LOW FLUID LEVEL WITH
VISIBLE LEAK.1. Loose power steering hose
fittings.1. Tighten the fitting to its specified torque.
2. Damaged or missing fitting seal,
gasket, or O-ring.2. Replace as necessary.
3. Power steering pump or power
steering gear leaking.3. Repair or replace the leaking component
as required.
AERATED FLUID. 1. Low fluid level.* 1. Fill power steering fluid reservoir to
proper level.
2. Air leak between power steering
fluid reservoir and pump.2. Inspect for proper sealing. Replace the
power steering pump (with reservoir).
3. Cracked power steering pump
housing.3. Replace the power steering pump.
RESERVOIR FLUID
OVERFLOW AND FLUID
IS MILKY IN COLOR1. Water contamination. 1. Drain the power steering fluid from the
system. Flush the system with fresh clean
power steering fluid, drain, then refill to the
proper level.
NOTE: * Extremely cold temperatures may cause
power steering fluid aeration, if the power steering
fluid is low.
POWER STEERING SYSTEM FLOW AND
PRESSURE TEST
The following procedure is to be used to test the
operation of the power steering system on this vehi-
cle. This test will provide the flow rate of the power
steering pump along with the maximum relief pres-
sure. This test is to be performed any time a power
steering system problem is present to determine if
the power steering pump or power steering gear is
not functioning properly. The following flow and pres-
sure test is performed using the Power Steering Ana-
lyzer Kit, Special Tool 6815 (Fig. 3), hoses, Special
Tools 6905 and 6959, and fittings from adapter kit,
Special Tool 6893.
(1) Assemble hoses on Power Steering Analyzer,
Special Tool 6815, as shown. Install Pressure Hose,
Special Tool 6905 (in 6893 kit), in the inlet fitting on
Power Steering Analyzer. Install Pressure Hose, Spe-
cial Tool 6713 (in 6815 kit) on Pressure Hose, Special
Tool 6905. Install Pressure Hose, Special Tool 6959,
in the outlet fitting on Power Steering Analyzer.CAUTION: To prevent personal injury, safety gog-
gles should be worn at all times when performing
any test procedures on the power steering system.
Fig. 3 Power Steering Analyzer With Hoses Installed
1 ± OUTLET
2 ± SPECIAL TOOL 6815
3 ± INLET
PLSTEERING 19 - 9
DIAGNOSIS AND TESTING (Continued)

(2) Install Adapter Fitting, Special Tool 6844, on
Pressure Hose, Special Tool 6713. Install Adapter Fit-
ting, Special Tool 6826, on Pressure Hose, Special
Tool 6959. Both Special Tool 6844 and 6826 can be
found in Adapter Set, Special Tool 6893 (Fig. 4).
(3) Unscrew the tube nut and disconnect the
power steering fluid pressure hose from the power
steering pump (Fig. 5).
(4) Connect Adapter Fitting, Special Tool 6844,
attached to pressure hose from inlet (gauge end) of
Power Steering Analyzer to the pressure fitting on
the power steering pump. Tighten the tube nut to a
torque of 34 N´m (25 ft. lbs.).
(5) Connect the vehicle's power steering fluid pres-
sure hose to Adapter Fitting, Special Tool 6826,
which should be already installed in the outlet hose
(valve end) of Power Steering Analyzer. Tighten the
tube nut to a torque of 34 N´m (25 ft. lbs.).
TEST PROCEDURE
(1) Completely open the valve on the Power Steer-
ing Analyzer flow meter.
(2) Start the engine and let idle long enough to cir-
culate power steering fluid through the analyzer and
hoses, until the air is out of the fluid. Shut the off
engine.
(3) Check the power steering fluid level and add
fluid as necessary. Start the engine again and let
idle.
(4) The analyzer gauge should read below 862 kPa
(125 psi). If above, inspect the hoses for restrictions
and repair as necessary. The initial pressure should
be in the range of 345-552 kPa (50-80 psi). The flow
meter should read between 1.1 and 1.3 GPM.CAUTION: The following test procedure step
involves testing maximum pump pressure output
and flow control valve operation. Do not leave valve
closed for more than five seconds as the pump
could be damaged.
NOTE: Power steering pump maximum relief pres-
sure is 9308 to 9998 kPa (1350 to 1450 psi.).
(5) Close the flow meter valve fully three times
and record highest pressure indicated each time.All
three readings must be above specifications
and within 345 kPa (50 psi) of each other.
²If the power steering pump pressure's are above
specifications, but not within 345 kPa (50 psi) of each
other, replace the power steering pump.
²If the pressure's are within 345 kPa (50 psi) of
each other, but below specifications, replace the
power steering pump.
If the power steering pump requires replacement,
refer to the section POWER STEERING PUMP
within this group for the removal and installation
procedure.
Fig. 4 Power Steering Analyzer Adapters 6893
Fig. 5 Hose At Pump
1 ± HOSE ROUTING CLIP
2 ± RETURN HOSE CLAMP
3 ± POWER STEERING PUMP AND RESERVOIR
4 ± PRESSURE HOSE TUBE NUT
19 - 10 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)

(4) Open the routing clips on the right side of the
power steering gear and remove the power steering
fluid pressure hose tube from the routing clips. At
the same time, remove the pressure hose tube from
the gear.
(5) Lower the vehicle.
(6) Remove the bolt securing the hose routing clip
in place on the right engine motor mount (Fig. 7).
Remove the power steering fluid pressure hose from
the routing clip.
(7) Back out the tube nut securing the power
steering fluid pressure hose to the power steering
pump and remove the hose from the pump (Fig. 7).
(8) Remove the power steering pressure hose from
the engine compartment.
INSTALLATION
(1) Install the power steering pressure hose into
the engine compartment from the top. First, guide
the pump end of the hose under the pump, then
route the rest of the hose along the right side of the
engine. Guide the gear end of the hose down behind
the back of the engine towards the power steering
gear.
(2) Using a lint free towel, wipe clean the open
power steering hose end and the power steeringpump port. Replace the used O-ring with new. Lubri-
cate the O-ring with power steering fluid.
(3) Attach the power steering fluid pressure hose
to the outlet fitting on the bottom of the power steer-
ing pump (Fig. 7). Tighten the pressure hose tube
nut to a torque of 34 N´m (25 ft. lbs.).
(4) Install the power steering fluid pressure hose
in the routing clip and attach the clip to the right
engine mount (Fig. 7). Tighten the hose routing clip
bolt to a torque of 12 N´m (105 in. lbs.).
(5) Raise the vehicle.
CAUTION: The power steering fluid hoses must
remain away from the exhaust system, vehicle com-
ponents, and unfriendly surfaces that can cause
possible damage to the power steering hoses.
(6) Using a lint free towel, wipe clean the open
power steering hose end and the power steering gear
port. Replace the used O-ring with new. Lubricate
the O-ring with power steering fluid.
(7) Attach the power steering fluid pressure hose
to the port on the power steering gear (Fig. 6). Start
the tube nut threads into the gear, but do not tighten
it at this time.
(8) Open the routing clips on the right side of the
power steering gear and install the power steering
fluid pressure hose into the routing clips. Close the
clips.
(9) Tighten the pressure hose tube nut at the gear
to a torque of 34 N´m (25 ft. lbs.).
(10) Lower the vehicle.
(11) 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.
(12) Check for leaks at all hose connections.
POWER STEERING FLUID RETURN 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) If the vehicle is equipped with a power steering
fluid cooler, remove the hose clamp securing the
return hose to the cooler. Slide the hose off the end of
the cooler tube.
Fig. 7 Power Steering Hoses At Pump
1 ± HOSE ROUTING CLIP
2 ± RETURN HOSE CLAMP
3 ± POWER STEERING PUMP AND RESERVOIR
4 ± PRESSURE HOSE TUBE NUT
19 - 12 STEERINGPL
REMOVAL AND INSTALLATION (Continued)