2000 DODGE NEON engine

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)

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)

(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)

(4) If the vehicle is not equipped with a power
steering fluid cooler:
²Remove the hose clamp securing the return hose
to the steel fitting in the outlet port on the power
steering gear (Fig. 6).
²Slide the hose off the end of the steel fitting.
²Pull the hose loose from the C-clamps on the two
routing clips located on the front of the steering gear
(Fig. 6).
(5) Lower the vehicle.
(6) Remove the bolt securing the hose routing clip
in place on the right engine mount (Fig. 7). Remove
the power steering fluid return hose from the routing
clip.
(7) Remove the hose clamp securing the return
hose to the power steering fluid reservoir (Fig. 7).
Slide the hose off the end of the reservoir fitting.
(8) Remove the power steering return hose from
the engine compartment.
INSTALLATION
(1) Slide a hose clamp onto the power steering
pump end of the hose far enough to clear the fitting
on the power steering fluid reservoir once the hose is
installed.
(2) Install the power steering return hose into the
engine compartment from the top. First, guide the
pump end of the hose onto the fitting on the power
steering fluid reservoir, then route the rest of the
hose along the right side of the engine (Fig. 7). Guide
the gear end of the hose down behind the back of the
engine towards the power steering gear.
(3) Expand the hose clamp and slide it onto the
fluid reservoir fitting. Secure the clamp once it is
past the bead formed into the fluid reservoir fitting.
(4) Install the power steering fluid return hose in
the hose 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 fitting or power steering fluid cooler port.
(7) Install a hose clamp onto the end of the hose
far enough to clear the fitting on the steering gear or
cooler once the hose is installed.
(8) If the vehicle is equipped with a power steering
fluid cooler, slide the hose onto the end of the cooler
tube. Install the hose clamp past the bead formed
into the cooler tube and secure in place.(9) If the vehicle is not equipped with a power
steering fluid cooler:
²Slide the hose onto the end of the steel fitting in
the steering gear outlet port (Fig. 6).
²Install the hose clamp past the bead formed into
the steel fitting and secure in place.
²Align and attach the hose to the C-clamps on
the two routing clips located on the front of the steer-
ing gear (Fig. 6).
(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 COOLER
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) Remove the hose clamp, attaching the power
steering fluid return hose to the power steering fluid
cooler. Remove the return hose from the cooler.
(4) Remove the hose clamp attaching the power
steering cooler fluid hose to the steel fitting in the
power steering gear outlet port (Fig. 8).
(5) Remove the two screws securing the cooler to
the front suspension crossmember. They are located
behind the cooler. They can be accessed from above.
(6) Open the routing clip on the right front of the
power steering gear housing and remove the cooler
tube from it.
(7) Remove the cooler from the vehicle.
INSTALLATION
(1) Slide a hose clamp onto the end of the power
steering cooler fluid hose far enough to clear the steel
fitting on the power steering gear once the hose is
installed.
(2) Slide the hose (with cooler attached) onto the
fitting on the steering gear, then align the tube on
back of the cooler with the open routing clip on the
right front of the power steering gear housing, and
snap it into place. Close the clip.
PLSTEERING 19 - 13
REMOVAL AND INSTALLATION (Continued)

(6) Start the engine and turn the steering wheel
several times stop-to-stop to bleed any air from the
fluid in the power steering system. Stop the engine,
check the fluid level, and inspect the system for
leaks.
SPECIFICATIONS
POWER STEERING FASTENER TORQUE
SPECIFICATIONS
DESCRIPTION TORQUE
POWER STEERING HOSE:
Tube Nuts............... 34N´m(25ft.lbs.)
Hose Routing Clip Bolt.... 12N´m(105 in. lbs.)
POWER STEERING COOLER:
Mounting Screws.......... 10N´m(90in.lbs.)
POWER STEERING FLUID PRESSURE
SWITCH:
Switch................... 8N´m(70in.lbs.)
POWER STEERING PUMP:
Pressure Hose Tube Nut.... 34N´m(25ft.lbs.)
Pressure Fitting........... 88N´m(65ft.lbs.)
Front Mounting Bolts..... 28N´m(250 in. lbs.)
Rear Mounting Bolt....... 28N´m(250 in. lbs.)
Rear Support Bracket To Engine Bolts . . 54 N´m
(40 ft. lbs.)
SPECIAL TOOLS
POWER STEERING
Power Steering Analyzer 6815
Adapters, Power Steering Analyzer 6893
PLSTEERING 19 - 15
REMOVAL AND INSTALLATION (Continued)

reduces the power required to drive the pump and
holds down temperature build-up.
When steering conditions exceed maximum pres-
sure requirements, such as when the wheels are
turned against the stops, the pressure built up in the
steering gear exerts pressure on the spring end of the
flow control valve. The high pressure lifts the relief
valve ball from its seat and allows oil to flow through
a trigger orifice located in the outlet fitting. This
reduces pressure on the spring end of the flow con-
trol valve which then opens and allows the oil to
return to the intake side of the pump. This action
limits maximum pressure output of the pump to a
safe level.
Under normal power steering pump operating con-
ditions, pressure requirements of the pump are below
maximum, causing the pressure relief valve to
remain closed.
POWER STEERING FLUID RESERVOIR
The power steering fluid reservoir is mounted on
the power steering pump using 3 bolts (Fig. 1). It
stores fluid for the power steering system.
The power steering fluid reservoir is considered an
integral part of the power steering pump and is not
serviced separately.
SERVICE PROCEDURES
POWER STEERING PUMP INITIAL OPERATION
CAUTION: The fluid level should be checked with
engine off to prevent injury from moving compo-
nents. Use only MoparTPower Steering Fluid. Do
not use automatic transmission fluid. Do not over-
fill.
Wipe the filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal temperature, approximately 21ÉC to 27ÉC
(70ÉF to 80ÉF).
(1) Fill the power steering fluid reservoir to the
proper level and let the fluid settle for at least two
minutes.
(2) Start the engine and let run for a few seconds,
then turn the engine off.
(3) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine.
(4) Raise the front wheels off the ground.
(5) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
stops.
(6) Add power steering fluid if necessary.
(7) Lower the vehicle and turn the steering wheel
slowly from lock to lock.(8) Stop the engine. Check the fluid level and refill
as required.
(9) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
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 PUMP
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) Remove battery cable from the negative post on
the battery.
(2) Siphon as much fluid as possible from the
power steering fluid reservoir.
(3) Remove the power steering pump drive belt
from the power steering pump pulley. Refer to
ACCESSORY DRIVE BELTS in the COOLING SYS-
TEM service manual group for the required removal
and installation procedure.
(4) Remove the hose clamp securing the return
hose to the power steering fluid reservoir. Slide the
hose off the end of the reservoir fitting. (Fig. 2).
(5) 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. 2).
PLSTEERING 19 - 17
DESCRIPTION AND OPERATION (Continued)