Dodge Neon / Neon SRT-4. Manual — part 300
gear ports. Replace the pressure hose used O-ring
with new. Lubricate the O-ring with power steering
fluid.
(13) Attach the power steering fluid pressure hose
to the pressure port on the power steering gear. Start
the tube nut threads into the gear, but do not tighten
them at this time. On vehicles equipped with a power
steering fluid cooler, reconnect the cooler line to the
gear in place of the power steering fluid return hose.
(14) Open the routing clips on the front of the
steering gear housing and install the power steering
fluid pressure hose into the routing clips.
(15) Place the cooler in mounting position and
snap the cooler tube going to the gear into the right
routing clip.
(16) Close both routing clips.
(17) Tighten the power steering fluid pressure
hose tube nut at the gear to a torque of 34 N·m (25
ft. lbs.).
(18) Install the two screws securing the cooler to
the front suspension crossmember. They are located
behind the cooler.
(19) Place the hose clamp on the hose far enough
from the end to clear the steel fitting on the gear. Do
the same for the fluid return hose on a vehicle that is
not equipped with a cooler.
(20) Push either hose listed in the above step onto
the steel fitting, then move and secure the clamp on
the hose past the bead on the steel fitting in the
steering gears outlet port.
(21) Route the fluid return hose along the front of
the steering gear, clipping it into place in the
C-clamps on the outside of the routing clips on the
front of the power steering gear housing.
(22) Reconnect the wiring harness connector from
the power steering fluid pressure switch (Fig. 6). Be
sure the locking tab on the wiring harness connector
is securely latched.
(23) Perform the following to each outer tie rod:
• Place the tie rod heat shield on the knuckle’s
steering arm, aligning the hole in the shield with the
hole in the knuckle and the tangs on the outside of
the shield with the outside configuration of the steer-
ing arm. The shield should now be facing outboard,
away from the power steering gear and tie rod (Fig.
4).
• Attach the outer tie rod end to its steering
knuckle.
• Start the attaching nut onto the stud of the
outer tie rod.
• While holding the stud of the tie rod stationary
with a wrench, tighten the attaching nut (Fig. 4).
• Using a crowfoot wrench attached to a torque
wrench, tighten the attaching nut to 55 N·m (40 ft.
lbs.).
(24) Install the tire and wheel assemblies back on
vehicle. Tighten the wheel mounting nuts to 135 N·m
(100 ft. lbs.) torque.
(25) Lower the vehicle to ground level.
(26) Install the dash-to-lower coupling seal in
place over the lower coupling’s plastic collar.
NOTE: Verify that grease is present on the lip of the
dash-to-coupling seal where it contacts the cou-
pling’s plastic collar.
(27) Inside the passenger compartment, place the
steering column in the full tilt-up position and
secure the tilt lever, then reconnect the steering
column lower coupling to the steering column upper
coupling (Fig. 3). Install the coupling pinch bolt and
tighten the pinch bolt nut to a torque of 28 N·m (250
in. lbs.). Install the pinch bolt retainer pin.
(28) Remove the steering wheel holder.
(29) While looking under the instrument panel at
the lower coupling, rotate the steering wheel back-
and-forth to verify that the lower coupling does not
squeak against the dash-to-coupling seal.
(30) Perform the POWER STEERING PUMP INI-
TIAL OPERATION service procedure to properly fill
and bleed the power steering system. (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE)
(31) Check for fluid leaks.
(32) Adjust the front toe setting on the vehicle.
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE)
INSTALLATION - RHD
Right-Hand-Drive power steering gear is typical of
Left-Hand-Drive. (Refer to 19 - STEERING/GEAR -
INSTALLATION - LHD)
TIE ROD - OUTER
REMOVAL
(1) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove the tire and wheel assembly from the
vehicle. (Refer to 22 - TIRES/WHEELS - REMOVAL)
(3) Loosen tie rod jam nut (Fig. 13). Thread the
jam nut far enough up the inner tie rod to pull the
collar away from the outer tie rod end. Pull the collar
off the end of the outer tie rod.
(4) Remove the nut attaching the outer tie rod end
to steering knuckle (Fig. 14). Remove the nut by
holding the tie rod stud stationary while loosening
and removing the nut with a wrench.
(5) Remove the outer tie rod from the steering
knuckle using Remover, Special Tool MB991113 (Fig.
15).
19 - 32
GEAR
PL/SRT-4
GEAR (Continued)
(6) Remove the tie rod heat shield.
(7) Remove the outer tie rod from the inner tie rod
by unthreading it.
INSTALLATION
(1) Install the jam nut on the inner tie rod threads
if it is not already installed (Fig. 13).
NOTE: Be sure the collar is installed on the inner
tie rod with the flat end of the collar against jam nut
and the open end of the collar facing the outer tie
rod end.
(2) Install the collar on the inner tie rod (Fig. 13).
(3) Thread the outer tie rod onto the inner tie rod.
(4) Position the collar around the end of the outer
tie rod (Fig. 13).
(5) Thread the jam nut down the inner tie rod far
enough to hold the collar in place on the outer tie
rod. Do not tighten the jam nut.
(6) Place the tie rod heat shield on the knuckle’s
steering arm, aligning the hole in the shield with the
hole in the knuckle and the tangs on the outside of
the shield with the outside configuration of the steer-
ing arm. The shield should now be facing outboard,
away from the power steering gear and tie rod (Fig.
14).
(7) Attach the outer tie rod end to the steering
knuckle.
(8) Start the attaching nut onto the stud of the
outer tie rod.
(9) While holding the stud of the tie rod stationary
with a wrench, tighten the attaching nut (Fig. 14).
(10) Using a crowfoot wrench attached to a torque
wrench, tighten the attaching nut to 75 N·m (55 ft.
lbs.).
(11) Install the tire and wheel assembly(Refer to
22 - TIRES/WHEELS - INSTALLATION). Tighten
wheel nut to a torque of 135 N·m (100 ft. lbs.).
(12) Lower the vehicle.
(13) Adjust the front toe setting on the vehicle.
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).
Fig. 13 Outer Tie Rod
1 - INNER TIE ROD
2 - OUTER TIE ROD JAM NUT
3 - STEERING KNUCKLE
4 - OUTER TIE ROD END
5 - COLLAR
6 - INNER TIE ROD SERRATION
Fig. 14 Tools On Outer Tie Rod Nut
1 - OUTER TIE ROD
2 - STUD
3 - NUT
Fig. 15 Tie Rod Removal From Knuckle
1 - OUTER TIE ROD
2 - STEERING KNUCKLE
PL/SRT-4
GEAR
19 - 33
TIE ROD - OUTER (Continued)
POWER STEERING PRESSURE
SWITCH
DESCRIPTION
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. 16).
OPERATION
The switch provides an input to the PCM during
periods of high pump load and low engine RPM; such
as during parking maneuvers.
When power steering pump pressure exceeds 2758
kPa (400 psi), the switch is open. The PCM increases
idle air flow through the IAC motor to prevent
engine stalling. The PCM sends 12 volts through a
resister to the sensor circuit to ground. When pump
pressure is low, the switch is closed.
REMOVAL
NOTE: Before proceeding, (Refer to 19 - STEERING
- WARNING).
(1) Disconnect negative battery cable from the neg-
ative post of the battery. Be sure cable is isolated
from negative post on battery.
(2) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(3) Locate the power steering fluid pressure switch
on the back side of the power steering gear (Fig. 16).
(4) Remove the vehicle wiring harness connector
from the power steering fluid pressure switch.
NOTE: When removing and installing the power
steering pressure switch, use a 7/8 inch deep well
socket. The deep well socket will prevent damage
to the plastic electrical connector area of the power
steering fluid pressure switch.
(5) Unscrew and remove the power steering fluid
pressure switch from the power steering gear.
INSTALLATION
(1) By hand, screw the power steering pressure
switch into the power steering gear until it is fully
seated (Fig. 16). Tighten the power steering pressure
switch to a maximum torque of 8 N·m (70 in. lbs.).
Over-torquing will result in stripping the threads out
of the power steering pressure switch port in the
steering gear.
(2) Install the vehicle wiring harness connector. Be
sure the latch on the wiring harness connector is
fully engaged with the locking tab on the power
steering pressure switch.
(3) Lower the vehicle.
(4) Fill the power steering fluid reservoir to the
correct fluid level. (Refer to 19 - STEERING/PUMP/
FLUID - STANDARD PROCEDURE)
(5) Connect the negative cable to the negative post
of the battery.
(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.
Fig. 16 Switch Location
1 - WIRING HARNESS CONNECTOR
2 - POWER STEERING GEAR
3 - POWER STEERING FLUID PRESSURE SWITCH
4 - REAR OF FRONT SUSPENSION CROSSMEMBER
19 - 34
GEAR
PL/SRT-4
PUMP
TABLE OF CONTENTS
page
page
PUMP
DESCRIPTION - POWER STEERING PUMP
STEERING PUMP INITIAL OPERATION
REMOVAL - POWER STEERING PUMP (2.0L
ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DISASSEMBLY - POWER STEERING PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
ASSEMBLY - POWER STEERING PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION - POWER STEERING PUMP
(2.0L ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION - 2.4L TURBO ENGINE
FLUID
FLUID COOLER
. . . . . . . . . . . . . . . . . . . . . . . . . 41
. . . . . . . . . . . . . . . . . . . . . . . . . . . 41
. . . . . . . . . . . . . . . 41
INSTALLATION - 2.4L TURBO ENGINE
HOSE - POWER STEERING PRESSURE
. . . . . . . . . . . . . . . . . 43
HOSE - POWER STEERING RETURN
. . . . . . . . . . . . . . . . . 44
HOSE - POWER STEERING PRESSURE/
RETURN
REMOVAL - 2.4L TURBO ENGINE
INSTALLATION - 2.4L TURBO ENGINE
PUMP
DESCRIPTION - POWER STEERING PUMP
The hydraulic pressure for operation of the power
steering gear is provided by a belt driven power
steering pump (Fig. 1) (Fig. 2). All applications use a
constant flow rate and displacement vane-type power
steering pump that is located on the front corner of
the engine.
No repair procedures are to be done on the internal
components of the power steering pump. The only
serviceable components of the power steering pump
are the power steering pump pulley and the pump
itself. The power steering fluid reservoir is serviced
with the pump.
Because of unique shaft bearings, flow control lev-
els or pump displacements, power steering pumps
may be used only on specific vehicle applications. Be
sure that all power steering pumps are only replaced
with pumps that are the correct replacement for that
specific application.
Fig. 1 Power Steering Pump - 2.0L Engine
1 - POWER STEERING FLUID RESERVOIR
2 - POWER STEERING PUMP
3 - PULLEY
4 - PUMP PRESSURE FITTING
PL/SRT-4
PUMP
19 - 35
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