1999 DODGE NEON ECU

The hose clamps have rolled edges to prevent the
clamp from cutting into the hose. Only use clamps
that are original equipment or equivalent. Other
types of clamps may cut into the hoses and cause
high pressure fuel leaks. Tighten hose clamps to 1
N´m (10 in. lbs.) torque.
QUICK-CONNECT FITTINGS
REMOVAL
When disconnecting a quick-connect fitting, the
retainer will remain on the fuel tube nipple.
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING A QUICK-CONNECT FIT-
TINGS. REFER TO THE FUEL PRESSURE RELEASE
PROCEDURE.
(1) Disconnect negative cable from battery.
(2) Perform Fuel Pressure Release Procedure.
Refer to the Fuel Pressure Release Procedure in this
section.
(3) Squeeze retainer tabs together and pull fuel
tube/quick-connect fitting assembly off of fuel tube
nipple. The retainer will remain on fuel tube.
INSTALLATION
CAUTION: Never install a quick-connect fitting
without the retainer being either on the fuel tube or
already in the quick-connect fitting. In either case,
ensure the retainer locks securely into the quick-
connect fitting by firmly pulling on fuel tube and fit-
ting to ensure it is secured.
(1) Using a clean lint free cloth, clean the fuel tube
nipple and retainer.
(2) Prior to connecting the fitting to the fuel tube,
coat the fuel tube nipple with clean 30 weight engine
oil.
(3) Push the quick-connect fitting over the fuel
tube until theretainer seats and a click is heard.
(4) The plastic quick-connect fitting has windows
in the sides of the casing. When the fitting com-
pletely attaches to the fuel tube, the retainer locking
ears and the fuel tube shoulder are visible in the
windows. If they are not visible, the retainer was not
properly installed (Fig. 14).Do not rely upon the
audible click to confirm a secure connection.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay remains energized
for either 7 minutes, until the test is stopped, or
until the ignition switch is turned to the Off posi-
tion.
(5) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
REMOVAL AND INSTALLATION
AUTOMATIC SHUTDOWN RELAY
The relay is located in the Power Distribution Cen-
ter (PDC) (Fig. 15). The PDC is located next to the
battery in the engine compartment. For the location
of the relay within the PDC, refer to the PDC cover
for location. Check electrical terminals for corrosion
and repair as necessary.
FUEL PUMP RELAY
The fuel pump relay is located in the PDC. The
inside top of the PDC cover has a label showing relay
and fuse location.
FUEL PUMP MODULE
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
(1) Drain the fuel. Refer to Draining Fuel Tank in
the Fuel Tank section of this group.
Fig. 14 Plastic Quick-Connect Fitting/Fuel Tube
Connection
Fig. 15 Power Distribution Center (PDC)
PLFUEL SYSTEM 14 - 11
SERVICE PROCEDURES (Continued)

(5) Position locating pin on power steering pres-
sure hose banjo fitting so it is against power steering
pump mounting bracket (Fig. 4). While holding locat-
ing pin against power steering pump bracket, torque
banjo bolt to 34 N´m (25 ft. lbs.).
POWER STEERING PUMP SUCTION PORT SEAL
The power steering pump does not require removal
from the engine for removal and replacement of the
suction port O-Ring seal.
REMOVE
(1) Remove power steering fluid supply hose from
power steering pump suction port fitting (Fig. 6).
(2) Remove bolt (Fig. 6) attaching power steering
pump suction port fitting to the power steering
pump.
(3) Remove the suction port fitting (Fig. 6) from
the power steering pump.(4) Remove and discard O-ring seal from suction
port fitting.
INSTALL
(1) Install new O-ring seal on suction fitting.
(2) Install suction port fitting in power steering
pump. Install and securely tighten the suction port
fitting attaching bolt.
(3) Install power steering fluid supply hose on suc-
tion port fitting, being sure hose clamp is installed on
hose past upset bead on suction port fitting.
REMOVAL AND INSTALLATION
POWER STEERING PRESSURE SWITCH
On vehicles equipped with power steering, a power
steering pressure switch is used to improve the vehi-
cle's idle quality. The pressure switch improves vehi-
cle idle quality, by controlling engine idle speed when
required.
The pressure switch functions by signaling the
power train control module, that the power steering
system is putting additional load on the engine. This
type of condition exists when turning the front tires
of the vehicle, when the vehicle is stationary and the
engine is at idle speed. When this condition is sensed
by the power train control module, through a signal
from the power steering pressure switch, engine idle
speed is increased. This increase in engine idle speed
compensates for the additional load, thus maintain-
ing the require engine idle speed and idle quality.
The power steering pressure switch (Fig. 7) is
mounted directly to the power steering gear on vehi-
cle's requiring its usage.
Fig. 4 Pressure Hose Attachment To Power Steering
Pump
Fig. 5 Pump Discharge And Flow Control Valve
Fitting
Fig. 6 Power Steering Pump Suction Port Fitting
19 - 12 STEERINGPL
SERVICE PROCEDURES (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)

(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)

Torque the 4 steering gear mounting bolts to 68 N´m
(50 ft. lbs.).
(2) Using the transmission jack, raise front sus-
pension crossmember and steering gear against body
and frame rails of vehicle. Start the 2 rear bolts into
tapping plates, attaching front suspension crossmem-
ber to body of vehicle (Fig. 13). Then install the 2
front bolts, attaching front suspension crossmember
to frame rails of vehicle (Fig. 13). Tighten the 4
mounting bolts, until front suspension crossmember
is against body of vehicle at the 4 mounting points.
Then torque the 4 mounting bolts to 2 N´m (20 in.
lbs.) to hold front suspension crossmember in posi-
tion.
CAUTION: When front suspension crossmember is
installed back in vehicle, crossmember MUST be
aligned with positioning marks previously scribbed
into body of vehicle (Fig. 16). This MUST be done to
maintain NET BUILD front suspension alignment
settings.
(3) Using a soft face hammer, tap front suspension
crossmember into position, until it is aligned with
the 2 previously scribbed positioning marks on body
of vehicle (Fig. 16). When front suspension cross-
member is correctly positioned, torque the 2 rear
crossmember/lower control arm mounting bolts to
163 N´m (120 ft. lbs.). Then torque the 2 front cross-
member to frame rail attaching bolts to 163 N´m (120
ft. lbs.) (Fig. 13).
(4) If vehicle is equipped with power steering,
install power steering fluid pressure and return
hoses into correct fluid ports on power steering gear
assembly (Fig. 10). Torque power steering fluid pres-
sure and return lines to steering gear tube nuts (Fig.
10) to 31 N´m (275 in. lbs.).(5) If vehicle is equipped with power steering,
install power steering pressure and return hose rout-
ing bracket and attaching screw on front suspension
crossmember (Fig. 9). Torque hose routing bracket to
crossmember attaching bolt (Fig. 9) to 23 N´m (17 ft,
lbs.).
(6) If the vehicle is equipped with power steering,
install vehicle wiring harness connector onto power
steering fluid pressure switch on steering gear
assembly (Fig. 8). Be sure locking tab on wiring har-
ness connector is securely latched to pressure switch.
(7) Install tie rod end into the steering knuckle.
Start tie rod end to steering knuckle attaching nut
onto stud of tie rod end. While holding stud of tie rod
end stationary, tighten tie rod end to steering
knuckle attaching nut (Fig. 6). Then using a crowfoot
and 11/32 socket (Fig. 17), torque tie rod end attach-
ing nut to 55 N´m (40 ft. lbs.).
(8) Install engine/transaxle bobble strut (Fig. 5)
back on front suspension crossmember bracket.
Install and securely tighten the dampener to cross-
member attaching bolt.
(9) Install the wheel and tire assemblies back on
vehicle. Tighten the wheel nuts to 135 N´m (100 ft.
lbs.) torque.
(10) Lower vehicle.
(11) From interior of vehicle, reconnect the steer-
ing gear coupler with the steering column shaft cou-
pler. Install steering gear coupler retaining pinch bolt
and torque to 28 N´m (250 in. lbs.).Be sure to
install the upper to lower steering coupler
retaining bolt, retention pin (Fig. 4).
CAUTION: Do not use automatic transmission
fluid.
(12) Fill power steering pump fluid reservoir to the
(Full-Cold) proper level.
Fig. 16 Crossmember Aligned With Positioning
Marks
Fig. 17 Torquing Tie Rod End Attaching Nut
PLSTEERING 19 - 31
REMOVAL AND INSTALLATION (Continued)

(23) Remove steering column from vehicle through
the drivers door of the passenger compartment. Use
care to avoid damaging the paint or interior trim.
INSTALL
(1) Install steering column into steering column
access opening in lower instrument panel.
(2) Install the vehicle wiring harness connectors,
into the ignition switch and clock spring assembly
(Fig. 19).
(3) Install vehicle wiring harness connectors into
multi-function switch and turn signal switch (Fig. 18)
on steering column assembly. Install routing clip
(Fig. 18) holding wiring harness to jacket of steering
column.
(4) Install the studs in the steering column sup-
port bracket, into the slots in the aluminum capsules
in the upper mounting bracket of the steering column
(Fig. 17). Partially install the 2 upper steering col-
umn assembly mounting bracket to support bracketattaching nuts (Fig. 17).Do not tighten the 2
mounting nuts at this time.
(5) Install and securely tighten the 2 nuts mount-
ing the steering column lower mounting bracket to
the steering column support bracket.
(6) Install the upper and lower steering column
shrouds onto the lock housing of the steering column
assembly. Install and securely tighten the 3 upper to
lower steering column shroud to lock housing attach-
ing screws (Fig. 15).
(7) Be sure both breakaway capsules are still fully
seated in the slots of the upper steering column
mounting bracket. Equally tighten both steering col-
umn mounting nuts, until upper steering column
mounting bracket is seated against support bracket.
Then tighten the 2 steering column upper mounting
bracket nuts to a torque of 17 N´m (150 in. lbs.).
(8) Tighten the steering column lower mounting
bracket nuts (2) to a torque of 17 N´m (150 in. lbs.).
(9) Assemble the steering column flex coupler to
the intermediate steering coupler (Fig. 16). Install
the steering coupler pinch bolt. Torque the pinch bolt
nut to 28 N´m (250 in. lbs.).Be sure to install
upper to lower steering coupler pinch bolt
retaining pin (Fig. 16).
(10) Install the lower instrument panel steering
column cover liner onto lower instrument panel.
Install and securely tighten the 3 liner to instrument
panel attaching screws (Fig. 7).
(11) Install lower instrument panel steering col-
umn cover (Fig. 6) on lower instrument panel. Install
and securely tighten the 4 screws (Fig. 6) attaching
steering column cover, to lower instrument panel.
CAUTION: Clock spring centering procedure MUST
be performed prior to installing steering wheel
assembly. If clock spring is not centered it may be
overextended, causing clock spring assembly to
become inoperative.
(12) Center the clock spring using the following
procedure.
²Depress the 2 plastic locking pins to disengage
clockspring locking mechanism.
²Keeping locking mechanism disengaged, rotate
the clockspring rotor in the CLOCKWISE DIREC-
TION to the end of the travel. Do not apply excessive
torque.
²From the end of travel, rotate the rotor 2 full
turns and an additional half turn in the counter-
clockwise direction. (The horn wire should end up at
the top and the squib wire at the bottom.) Engage
the clockspring locking mechanism.
Fig. 18 Steering Column Wiring Connections
Fig. 19 Steering Column Wiring Connections
PLSTEERING 19 - 41
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)

(5) Remove cable to bracket retaining clips at tran-
saxle.
CAUTION: It is recommended that new cable retain-
ing clips be used for reinstallation.
(6) Pull cables up out of transaxle bracket.
(7) Remove console from vehicle. Refer to Group
23, Body.
(8) Remove floor pan grommet retaining nuts (Fig.
9).
(9) Remove cable retaining clips at shifter (Fig.
10).
CAUTION: It is recommended that new cable retain-
ing clips be used for reinstallation.
(10) Disconnect shift cables from shifter. Pry with
equal force on both sides of shifter cable isolator
bushings to avoid damaging bushings.(11) Lift vehicle on hoist. Remove self-tapping
screw securing grommet plate to underbody heat
shield and floor pan (Fig. 11).
Fig. 7 Selector Cable Removal
Fig. 8 Crossover Cable Removal
Fig. 9 Grommet Retaining Nuts (Interior)
Fig. 10 Cable Retaining Clips
Fig. 11 Grommet Retaining Screw (Underbody)
PLTRANSAXLE 21 - 5
REMOVAL AND INSTALLATION (Continued)