2000 DODGE NEON Service Repair Manual

(4) Connect electrical connector to idle air control
motor.
(5) Connect negative cable to battery.
MAP SENSOR
The MAP sensor attaches to the intake manifold
plenum (Fig. 35).
REMOVAL
(1) Disconnect the electrical connector from the
MAP sensor.
(2) Remove sensor mounting screws.
(3) Remove sensor.
INSTALLATION
(1) Insert sensor into intake manifold while mak-
ing sure not to damage O-ring seal.(2) Tighten mounting screws to 4.5 N´m (40 in.
lbs.) torque for plastic manifold.
(3) Attach electrical connector to sensor.
POWERTRAIN CONTROL MODULE (PCM)
REMOVAL
(1) Disconnect the negative battery cable (Fig. 36).
(2) Remove the air cleaner box, refer to the air
cleaner box section.
(3) Remove the gray and black connector from the
PCM (Fig. 37).
(4) Remove the harness clip bracket from PCM
bracket (Fig. 38).
Fig. 34 Servicing Idle Air Control Motor
Fig. 35 MAP Sensor
Fig. 36 Battery Cable
Fig. 37 Powertrain Control Module (PCM)
1 ± PCM
14 - 44 FUEL SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

(5) Remove the nut from the upper bracket mount.
(6) Raise vehicle and support on hoist.
(7) Remove 2 lower bracket bolts (Fig. 39).
(8) Remove 4 screws from bracket and remove
bracket from PCM (Fig. 40).
INSTALLATION
(1) Install bracket to PCM and tighten screws.
(2) Install PCM and bracket to body and tighten
the 2 lower bolts.
(3) Lower vehicle.
(4) Install upper bracket nut and tighten.
(5) Clip in wiring harness bracket.
(6) Install gray and black connectors to the PCM.
(7) Install the air cleaner box, refer to the air
cleaner box section.(8) Connect the negative battery cable.
UPSTREAM HEATED OXYGEN SENSOR
REMOVAL
(1) Raise and support vehicle.
(2) Unplug sensor connector.
(3) Remove sensor using an oxygen sensor crow
foot wrench such as Snap-On tool YA8875 or equiva-
lent (Fig. 41).
(4) After removing the sensor, the exhaust mani-
fold threads must be cleaned with an 18 mm X 1.5 +
6E tap. If reusing the original sensor, coat the sensor
threads with an anti-seize compound such as Loctitet
771-64 or equivalent.
Fig. 38 PCM Wiring Bracket
Fig. 39 Lower Mounting Bolts
Fig. 40 PCM Bracket Screws
Fig. 41 Upstream Heated Oxygen Sensor Removal/
Installation
1 ± EXHAUST PIPE FLANGE
2 ± CROW FOOT WRENCH
3 ± UPSTREAM OXYGEN SENSOR
PLFUEL SYSTEM 14 - 45
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
New sensors have compound on the threads and do
not require an additional coating.
(1) Install sensor using an oxygen sensor crow foot
wrench such as Snap-On tool YA8875 or equivalent
(Fig. 41). Tighten the sensor to 28 N´m (20 ft. lbs.)
torque.
(2) Plug sensor connector.
(3) Lower vehicle.
DOWNSTREAM HEATED OXYGEN SENSOR 1/2
The downstream heated oxygen sensor threads into
the exhaust outlet pipe behind the catalytic convertor
(Fig. 42).
REMOVAL
(1) Raise vehicle.
(2) Disconnect electrical connector from harness.
(3) Disconnect sensor electrical harness from clips
along body.
(4) Remove sensor using an oxygen sensor crow
foot wrench such as Snap-On tool YA8875 or equiva-
lent (Fig. 43).
(5) After removing the sensor, the exhaust mani-
fold threads must be cleaned with an 18 mm X 1.5 +
6E tap. If reusing the original sensor, coat the sensor
threads with an anti-seize compound such as Loctitet
771-64 or equivalent.
INSTALLATION
New sensors have compound on the threads and do
not require an additional coating.
(1) Install sensor using an oxygen sensor crow foot
wrench such as Snap-On tool YA8875 or equivalent
(Fig. 43). Tighten the sensor to 28 N´m (20 ft. lbs.)
torque.
(2) Connect sensor electrical harness from clips
along body.
(3) Connect electrical connector to harness.
(4) Lower vehicle.
AIR CLEANER BOX
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
(Fig. 44).
(4) Move air duct out of the way.
(5) Remove the bolt and nut from the air cleaner
box.
(6) Remove wiring harness from the clips on the
air cleaner box.
(7) Remove the wiring clip from the front of the air
cleaner box.(8) Remove the 4 bolts from the air cleaner box to
throttle body.
(9) Pull air cleaner box up and off of stud and bat-
tery tray and remove from vehicle.
INSTALLATION
(1) Install air cleaner box. Make sure that it is on
the battery tray tab in the back and on the stud on
the side.
(2) Install the bolts to the throttle body and
tighten.
(3) Install the nut and bolt for air cleaner box and
tighten.
(4) Install the wiring clip in the front of the air
cleaner box.
Fig. 42 Downstream Heated Oxygen Sensor
1 ± CATALYTIC CONVERTOR
2 ± DOWNSTREAM OXYGEN SENSOR
Fig. 43 Downstream Heated Oxygen Sensor
Removal/Installation
1 ± DOWNSTREAM HEATED OXYGEN SENSOR
2 ± CATALYTIC CONVERTOR
14 - 46 FUEL SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

(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