1999 DODGE NEON Service Repair Manual

(3) Remove air cleaner element from front housing
(Fig. 106).
INSTALLATION
(1) Install air cleaner element into front housing.
(2) Rotate front of housing forward then lower into
place and locate tabs in slots. Fasten clasps on top of
air cleaner housing.
(3) Install air intake duct at air cleaner and intake
manifold.
ENGINE COOLANT TEMPERATURE SENSOR
The engine coolant temperature sensor threads
into the rear of the cylinder head (Fig. 107) or (Fig.
108).
REMOVAL
(1) With the engine cold, drain coolant until level
drops below cylinder head. Refer to Group 7, Cooling
System.
(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 Group 7, Cooling
System.
VEHICLE SPEED SENSOR
The vehicle speed sensor is located in the transmis-
sion extension housing (Fig. 109).
REMOVAL
(1) Disconnect electrical connector from sensor.
(2) Remove the sensor mounting bolt.
(3) Lift the sensor out of the transaxle extension
housing. Ensure the O-ring was removed with the
sensor.
Fig. 104 Air Intake Duct
Fig. 105 Removal/Installation of Air Inlet Duct
Fig. 106 Removal/Installation Air Cleaner Front
Housing and Element
Fig. 107 Engine Coolant Temperature SensorÐ
SOHC
14 - 56 FUEL SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

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
For removal/installation procedures refer to Group
8D- Ignition System, Service Procedures.
SPECIFICATIONS
VECI LABEL
If anything differs between the specifications found
on the Vehicle Emission Control Information (VECI)
label and the following specifications, use specifica-
tions on VECI label. The VECI label is located in the
engine compartment.
TORQUE
DESCRIPTION TORQUE
Air Cleaner Wingnut..........1.5 N´m (15 in. lbs.)
Air Cleaner Mount. Stud-To-Thrott. Body .10 N´m (90
in. lbs.)
Crankshaft Position Sensor Mounting Bolts.8 N´m (70
in. lbs.)
Engine Coolant Temperature Sensor .18 N´m (165 in.
lbs.)
IAC Motor-To-Throttle Body Bolts .7 N´m (60 in. lbs.)
MAP/IAT Sensor..............2N´m(20in.lbs.)
MAP/IAT Sensor..............3N´m(30in.lbs.)
Oxygen Sensor...............28N´m(20ft.lbs.)
Powertrain Control Module (PCM) Mounting Screws.4
N´m (35 in. lbs.)
Throttle Cable Cover.........4.5 N´m (40 in. lbs.).
Throttle Body Mounting Bolts . .23 N´m (200 in. lbs.)
Throttle Position Sensor Mounting Screws .2 N´m (20
in. lbs.)
Vehicle Speed Sensor Mounting Bolt .2.2 N´m (20 in.
lbs.)
SPECIAL TOOLS
FUEL
Fig. 108 Engine Coolant Temperature SensorÐ
DOHCFig. 109 Vehicle Speed Sensor
Extractor C±4334Pressure Gauge Assembly C±4799±B
PLFUEL SYSTEM 14 - 57
REMOVAL AND INSTALLATION (Continued)

Fuel Pressure Test Adapter 6539
Spanner Wrench 6856
Metering Orifice
Fuel Line Tool
Fuel Line Adapter
Fuel Line Adapter 1/4
O2S (Oxygen Sensor) Remover/InstallerÐC-4907
14 - 58 FUEL SYSTEMPL
SPECIAL TOOLS (Continued)

FUEL SYSTEMÐ1.8L ENGINE
CONTENTS
page
GENERAL INFORMATION
FUEL SYSTEMÐ1.8L SOHC ENGINE....... 1
GENERAL INFORMATION
FUEL SYSTEMÐ1.8L SOHC ENGINE
The fuel delivery system used on the 1.8L SOHC
engine operates the same as the fuel system used on
the 2.0L SOHC engine. It also contains the samecomponents as the 2.0L engine, and the service pro-
cedures are the same. Refer to group 14 for the 2.0L
engine in this manual for a complete description of
the fuel system and its service procedures.
PLFUEL SYSTEMÐ1.8L ENGINE 14 - 1

STEERING
CONTENTS
page page
GENERAL INFORMATION................... 1
POWER STEERING PUMP.................. 9STEERING COLUMN...................... 35
STEERING GEAR........................ 26
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
STEERING SYSTEM AND COMPONENT
DESCRIPTION......................... 1DIAGNOSIS AND TESTING
STEERING SYSTEM DIAGNOSIS CHARTS..... 2
GENERAL INFORMATION
STEERING SYSTEM AND COMPONENT
DESCRIPTION
This vehicle comes with power steering as stan-
dard equipment and is the only steering system
available.
The power steering system consists of these six
major components. Power Steering Pump, Power
Steering Gear, Power Steering Reservoir, Power
Steering Supply and Pressure Hoses, and Power
Steering Fluid Return Hose. Turning of the steering
wheel is converted into linear travel through themeshing of the helical pinion teeth with the rack
teeth. Power assist steering is provided by an open
center, rotary type control valve. It is used to direct
oil 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
oil behind the integral rack piston, which in turn,
builds up hydraulic pressure and assists in the turn-
ing effort.
PLSTEERING 19 - 1

DIAGNOSIS AND TESTING
STEERING SYSTEM DIAGNOSIS CHARTS
STEERING NOISE
There is some noise in all power steering systems.
One of the most common is a hissing sound evidentat standstill parking. 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 in high velocity fluid passing valve orifice
edges. There is no relationship between this noise
and performance of the steering. Hiss may be
expected when steering wheel at end of travel or
slowly turning at standstill.
CONDITION POSSIBLE CAUSES CORRECTION
Objectionable Hiss Or Whistle 1. Damaged or mispositioned
steering column coupler to dash
panel seal.1. Check for proper seal between
steering column coupler and dash
seal.
2. Noisy valve in power steering
gear.2. Replace steering gear assembly.
Rattle Or Clunk 1. Steering gear loose on front
suspension crossmember.1. Check steering gear to front
suspension crossmember mounting
bolts. Tighten to the specified torque
if found to be loose.
2. Front suspension crossmember to
frame bolts or studs loose.2. Tighten the front suspension
crossmember attaching bolts or
studs 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 to front
suspension crossmember bolts.4. Tighten control arm mounting
bolts to the specified torques.
5. Loose strut assembly to body
attaching bolts or nuts.5. Check upper strut mount to body
attaching bolts or nuts for looseness.
If required, tighten 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. Noise internal to power steering
gear.7. Replace steering gear assembly.
8. Damaged front suspension
crossmember.8. Replace front suspension
crossmember.
Chirp or squeal (in the area of the
power steering pump). Particularly
noticeable at full wheel travel and
during standstill parking.1. Loose power steering pump drive
belt.1. Adjust power steering pump drive
belt to specified tension.
19 - 2 STEERINGPL

CONDITION POSSIBLE CAUSES CORRECTION
Power steering pump growl results from the development of high pressure fluid flow. Normally this noise should
not be high enough to be objectionable. Abnormal situations, such as a low oil level causing aeration or hose
touching the vehicle body, can create a noise level that could bring complaints.
Whine Or Growl (Pump Noise) 1. Low fluid level. 1. Fill power steering fluid reservoir
to proper level and perform leakage
diagnosis. (Recheck fluid level after
power steering fluid is free of air.)
2. Power steering hose touching
vehicle body or frame.2. Reposition power steering hose.
Replace hose if tube ends are bent.
3. Extreme wear of power steering
pump internal parts.3. Replace power steering pump and
flush system.
Sucking Air Sound 1. Loose clamp on power steering
fluid low pressure 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 perform leakage
diagnosis.
4. Air leak between power steering
fluid reservoir and power steering
pump.4. Inspect and or replace power
steering fluid reservoir as required.
SQUEAK OR RUBBING SOUND 1. Sound coming from steering
column.1.Check for squeak in steering
column. Inspect for contact between
shroud, intermediate shaft, column,
and steering wheel. Realign if
necessary.
2. Check for lack or grease on
steering column dash panel to lower
coupler seal.
2. Sound internal to steering gear. 1. Replace steering gear assembly.
SCRUBBING OR KNOCKING
SOUND1. Incorrect tire size. 1. Verify that tire size on vehicle is
the same as originally supplied.
2. Check clearance between tires
and other vehicle components,
through the full travel of the
suspension.2. Correct as necessary.
3. Check for interference between
steering gear and other
components.3.Correct as necessary.
4.Incorrect steering gear supplied. 4. Replace steering gear with correct
steering gear for specific vehicle.
PLSTEERING 19 - 3
DIAGNOSIS AND TESTING (Continued)