Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Dodge Neon 1997.1999.2000.2004 Approved Dodge Neon 1997 EPL_19

<< Back | Home

Most service manuals and schematics are PDF files, so You will need Adobre Acrobat Reader to view : Acrobat Download Some of the files are DjVu format. Readers and resources available here : DjVu Resources
For the compressed files, most common are zip and rar. Please, extract files with Your favorite compression software ( WinZip, WinRAR ... ) before viewing. If a document has multiple parts, You should download all, before extracting.
Good luck. Repair on Your own risk. Make sure You know what You are doing.




Image preview - the first page of the document
EPL_19


>> Download EPL_19 documenatation <<

Text preview - extract from the document
PL                                                                                                      STEERING        19 - 1



                                                     STEERING
                                                        CONTENTS

                                                         page                                                             page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1         STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 35
POWER STEERING PUMP . . . . . . . . . . . . . . . . 10            STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . 27



                                         GENERAL INFORMATION

                                                             INDEX
                                                         page                                                             page

GENERAL INFORMATION                                               DIAGNOSIS AND TESTING
 STEERING SYSTEM AND COMPONENT                                      STEERING SYSTEM DIAGNOSIS CHARTS . . . . 1
  DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 1

GENERAL INFORMATION                                               DIAGNOSIS AND TESTING
STEERING SYSTEM AND COMPONENT                                     STEERING SYSTEM DIAGNOSIS CHARTS
DESCRIPTION
   This vehicle comes with power steering as stan-                STEERING NOISE
dard equipment and is the only steering system                      There is some noise in all power steering systems.
available.                                                        One of the most common is a hissing sound evident
   The power steering system consists of these six                at standstill parking. Hiss is a very high frequency
major components. Power Steering Pump, Power                      noise similar to that experienced while slowly closing
Steering Gear, Power Steering Reservoir, Power                    a water tap. The noise is present in every valve and
Steering Supply and Pressure Hoses, and Power                     results in high velocity fluid passing valve orifice
Steering Fluid Return Hose. Turning of the steering               edges. There is no relationship between this noise
wheel is converted into linear travel through the                 and performance of the steering. Hiss may be
meshing of the helical pinion teeth with the rack                 expected when steering wheel at end of travel or
teeth. Power assist steering is provided by an open               slowly turning at standstill.
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.
19 - 2   STEERING                                                                                               PL
DIAGNOSIS AND TESTING (Continued)


           CONDITION                          POSSIBLE CAUSES                          CORRECTION
Objectionable Hiss Or Whistle         1. Damaged or mispositioned           1. Check for proper seal between
                                      steering column coupler to dash       steering column coupler and dash
                                      panel seal.                           seal.
                                      2. Noisy valve in power steering      2. Replace steering gear assembly.
                                      gear.
Rattle Or Clunk                       1. Steering gear loose on front       1. Check steering gear to front
                                      suspension crossmember.               suspension crossmember mounting
                                                                            bolts. Tighten to the specified torque
                                                                            if found to be loose.
                                      2. Front suspension crossmember to    2. Tighten the front suspension
                                      frame bolts or studs loose.           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   4. Tighten control arm mounting
                                      suspension crossmember bolts.         bolts to the specified torques.
                                      5. Loose strut assembly to body       5. Check upper strut mount to body
                                      attaching bolts or nuts.              attaching bolts or nuts for looseness.
                                                                            If required, tighten to the specified
                                                                            torques.
                                      6. Power steering fluid pressure      6. Adjust hose to proper position by
                                      hose touching the body of the         loosening, repositioning, and
                                      vehicle.                              tightening fitting to specified torque.
                                                                            Do not bend tubing.
                                      7. Noise internal to power steering   7. Replace steering gear assembly.
                                      gear.
                                      8. Damaged front suspension           8. Replace front suspension
                                      crossmember.                          crossmember.
Chirp or squeal (in the area of the   1. Loose power steering pump drive    1. Adjust power steering pump drive
power steering pump). Particularly    belt.                                 belt to specified tension.
noticeable at full wheel travel and
during standstill parking.
PL                                                                                            STEERING        19 - 3
DIAGNOSIS AND TESTING (Continued)

           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        2. Reposition power steering hose.
                                     vehicle body or frame.                 Replace hose if tube ends are bent.
                                     3. Extreme wear of power steering      3. Replace power steering pump and
                                     pump internal parts.                   flush system.
Sucking Air Sound                    1. Loose clamp on power steering       1. Tighten or replace hose clamp.
                                     fluid low pressure hose.
                                     2. Missing O-Ring on power steering    2. Inspect connection and replace
                                     hose connection.                       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     4. Inspect and or replace power
                                     fluid reservoir and power steering     steering fluid reservoir as required.
                                     pump.
SQUEAK OR RUBBING SOUND              1. Sound coming from steering          1.Check for squeak in steering
                                     column.                                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                1. Incorrect tire size.                1. Verify that tire size on vehicle is
SOUND                                                                       the same as originally supplied.
                                     2. Check clearance between tires       2. Correct as necessary.
                                     and other vehicle components,
                                     through the full travel of the
                                     suspension.
                                     3. Check for interference between      3.Correct as necessary.
                                     steering gear and other
                                     components.
                                     4.Incorrect steering gear supplied.    4. Replace steering gear with correct
                                                                            steering gear for specific vehicle.
19 - 4   STEERING                                                                                           PL
DIAGNOSIS AND TESTING (Continued)
BINDING STICKING SEIZED

          CONDITION                   POSSIBLE CAUSES                            CORRECTION
CATCHES, STICKS IN CERTAIN     1. Low power steering fluid level.    1. Fill power steering fluid reservoir
POSITIONS OR IS DIFFICULT TO                                         to specified level and perform
TURN.                                                                leakage diagnosis.
                               2. Tires not inflated to specified    2. Inflate tires to the specified
                               pressure.                             pressure.
                               3. Lack of lubrication in front       3. Lubricate ball joints if ball joints
                               suspension control arm 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 front       4. Lubricate tie rod ends if they are
                               suspension outer tie rod ends.        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    5. Tighten the power steering pump
                               belt.                                 drive belt to the specified tension.
                                                                     See accessory drive in service
                                                                     manual.
                               6. Faulty power steering pump flow    6. Replace power steering pump.
                               control. (Verify cause using Power
                               Steering Pump Test Procedure.)
                               7. Excessive friction in steering     7. Correct condition. (See Steering
                               column or intermediate shaft.         Column Service Procedure)
                               8. Steering column coupler binding.   8. Realign the steering column to
                                                                     eliminate the binding condition.
                               9. Binding upper strut bearing.       9. Correct binding condition in strut
                                                                     bearing.
                               10 Excessive friction in steering     10 Replace steering gear assembly.
                               gear.
PL                                                                                     STEERING        19 - 5
DIAGNOSIS AND TESTING (Continued)
SHAKE SHUDDER VIBRATION

        CONDITION                   POSSIBLE CAUSES                              CORRECTION
VIBRATION OF THE STEERING   1. Air in the fluid of the power         1. Steering shudder can be expected
WHEEL AND/OR DASH DURING    steering system.                         in new vehicles and vehicles with
DRY PARK OR LOW SPEED                                                recent steering system repairs.
STEERING MANEUVERS.                                                  Shudder should improve after the
                                                                     vehicle has been driven several
                                                                     weeks.
                            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.                    4. Check that the inner to outer tie
                                                                     rod jam nut for is tight. If required,
                                                                     tighten the jam nut to the specified
                                                                     torque.
                            5.Overcharged air conditioning           5.Check air conditioning pump head
                            system.                                  pressure. (See Air Conditioning
                                                                     Refrigerant System Diagnosis)

LOW ASSIST, NO ASSIST, HARD STEERING

        CONDITION                   POSSIBLE CAUSES                              CORRECTION
STIFF, HARD TO TURN,        1. Tires not properly inflated.          1. Inflate tires to specified pressure.
SURGES, MOMENTARY
INCREASE IN EFFORT WHEN
TURNING.
                            2. Low power steering fluid level.       2. Add power steering fluid as
                                                                     required to power steering fluid
                                                                     reservoir to obtain proper level.
                                                                     Perform leakage diagnosis on power
                                                                     steering system.
                            3. Loose power steering pump drive       3. Adjust the power steering pump
                            belt.                                    drive belt to the specified tension. If
                                                                     drive belt is defective replace and
                                                                     correctly tension.
                            4. Lack of lubrication in control arm    4. Lubricate ball joints if ball joints
                            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.
                            5. Low power steering pump               5. Verify cause using the Power
                            pressure. (Verify using Power            Steering System Test Procedure.
                            Steering System Test Procedure)          Replace the power steering pump if
                                                                     necessary.
                            6. High internal leak in steering gear   6. Check steering system using the
                            assembly.                                Power Steering System Test
                                                                     Procedure. If steering gear is
                                                                     defective replace steering gear.
19 - 6   STEERING                                                                                        PL
DIAGNOSIS AND TESTING (Continued)
POOR RETURN TO CENTER

          CONDITION                POSSIBLE CAUSES                            CORRECTION
STEERING WHEEL DOES NOT    1. Tires not                          1. Inflate tires to specified pressure.
WANT TO RETURN TO CENTER   inflated to specified pressure.
POSITION.
                           2. Improper front wheel alignment.    2. Check and adjust as necessary.
                           3. Lack of lubrication in front       3. Lubricate ball joints if ball joints
                           suspension control arm ball joints.   are not a lubricated for life type of
                                                                 ball joint. If ball joint is a lubricated
                                                                 for life ball joint, replace ball joint or
                                                                 control arm.
                           4. Steering column U-joints           4. Realign steering column U-joints.
                           misaligned.
                           5.                                    5. Reposition dash cover.
                           Mispositioned dash cover.
                                                                 To
                                                                 evaluate items 6 and 7, disconnect
                                                                 the intermediate shaft. Turn the
                                                                 steering wheel and feel or listen for
                                                                 internal rubbing in steering column.
                           6. Steering wheel rubbing.            6. Adjust steering column shrouds to
                                                                 eliminate rubbing condition.
                           7. Damaged, mis-positioned or         7. Determine condition which exists
                           un-lubricated steering column         and correct.
                           coupler to dash seal.
                           8. Binding upper strut bearing.       8. Correct
                                                                 binding condition in strut bearing.
                           9. Tight shaft bearing                9. Replace the steering column
                           in steering column assembly.          assembly.
                           10. Excessive friction in steering    10. Replace steering column coupler.
                           column coupler.
                           11. Excessive friction in steering    11. Replace steering gear.
                           gear.
PL                                                                               STEERING       19 - 7
DIAGNOSIS AND TESTING (Continued)
LOOSE STEERING

        CONDITION                   POSSIBLE CAUSES                        CORRECTION
EXCESSIVE STEERING WHEEL    1. Air in the fluid of the power    1. Fill power steering fluid reservoir
KICKBACK OR TO MUCH         steering system.                    to the specified level. Perform
STEERING WHEEL FREE PLAY.                                       procedure to bleed the air out of the
                                                                power steering system. Perform
                                                                leakage diagnosis.
                            2. Steering gear loose on front     2. Check steering rear to front
                            suspension crossmember.             suspension crossmember mounting
                                                                bolts. Tighten to specified torque if
                                                                found to be loose.
                            3. Worn, broken or loose steering   3. Check for worn universal joint,
                            column to steering gear coupler.    broken isolator or loose fasteners.
                            4. Free play in steering column.    4.Check components of the steering
                                                                system and repair or replace as
                                                                required.
                            5. Loose front suspension control   5. Check and or replace the ball joint
                            arm ball joints.                    or control arm as required.
                            6. Loose steering knuckle to ball   6. Check pinch bolts and tighten if
                            joint stud pinch bolt.              required to specified torque.
                            7. Front wheel bearings loose or    7. Tighten hub nut to specified
                            worn.                               torque or replace with new parts as
                                                                necessary.
                            8. Loose outer tie rod ends.        8. Check free play of outer tie rod
                                                                ends and replace if required.
                            9. Loose inner tie rod ends.        9. Replace steering gear assembly.
                            10 Defective steering gear rotary   10. Replace steering gear assembly.
                            valve.
19 - 8   STEERING                                                                                           PL
DIAGNOSIS AND TESTING (Continued)
VEHICLE LEADS TO THE SIDE

          CONDITION                 POSSIBLE CAUSES                              CORRECTION
STEERING WHEEL DOES NOT     1. Radial tire lead.                      1.Rotate tires as recommended in
WANT RETURN TO CENTER                                                 the Tire And Wheel Group of this
POSITION.                                                             service manual.
                            2. Front suspension misaligned.           2. Align the front suspension as
                                                                      required. Refer to the Wheel
                                                                      Alignment Procedure in the
                                                                      Suspension Group of this service
                                                                      manual for the required wheel
                                                                      alignment procedure.
                            3. Wheel braking.                         3. Check for dragging brakes. Refer
                                                                      to the procedures in the Brake
                                                                      Group of this service manual.
                            4. Unbalanced steering gear valve.        4. Replace steering gear.
                            (If this is the cause, the steering
                            efforts will be very light in direction
                            of lead and heavier in the opposite
                            direction.
STEERING WHEEL HAS FORE     1. Steering wheel to steering column      1. Tighten the retaining nut to its
AND AFT LOOSENESS.          shaft retaining nut not properly          specified torque specification.
                            tightened and torqued.
                            2. Steering column lower bearing          2. Replace steering column.
                            spring retainer slipped on steering
                            column shaft.
PL                                                                                  STEERING        19 - 9
DIAGNOSIS AND TESTING (Continued)
POWER STEERING FLUID LEAK

        CONDITION                    POSSIBLE CAUSES                          CORRECTION
LOW FLUID LEVEL WITH: NO     1. Overfilled power steering pump    1. Adjust the power steering fluid fill
VISIBLE SIGNS OF A LEAK ON   fluid reservoir.                     to the correct level.
THE STEERING GEAR, POWER
STEERING PUMP, FLOOR OR
ANYWHERE ELSE.
LOW FLUID LEVEL WITH:        2. Power steering hose connections   2. Check for loose fittings and if
VISIBLE LEAK ON STEERING     at the power steering pump or        found, tighten the fitting to its
GEAR, POWER STEERING         steering gear.                       specified torque. If fittings are tight
PUMP, FLOOR OR ANYWHERE                                           examine the fittings for damaged or
ELSE.                                                             missing O-ring seals and replace as
                                                                  required.
                             3. Power steering pump or power      3. Identify the location of the leak
                             steering gear leaking.               and repair or replace the component
                                                                  as required. Refer to Power Steering
                                                                  Pump and/or Power Steering Gear in
                                                                  this group of the service manual for
                                                                  required procedures.

FOAMY OR MILKY POWER STEERING FLUID

        CONDITION                    POSSIBLE CAUSES                          CORRECTION
AERATION AND OVERFLOW OF     1. Air leaks.                        1. Check for an air leak into the
FLUID.                                                            power steering system as described
                                                                  under Sucking Air Diagnosis and
                                                                  correct condition.
                             2. Low fluid level.                  2. Extremely cold temperatures may
                                                                  cause power steering fluid aeration if
                                                                  the power steering fluid is low. Add
                                                                  power steering fluid as required to
                                                                  bring level up to specification.
                             3. Cracked power steering pump       3. Remove power steering pump
                             housing.                             from vehicle and inspect the power
                                                                  steering pump housing for cracks. If
                                                                  a defect in the housing is found,
                                                                  replace the power steering pump.
                             4. Water contamination.              4. Drain the power steering fluid
                                                                  from the system if there is evidence
                                                                  of contamination. Then refill the
                                                                  system with fresh clean power
                                                                  steering fluid.
                                                POWER STEERING SHAFT
                                                     POWERPUMP PUMP
                                                            STEERING
                                                             HOUSING
POWER STEERING PUMP FLUID SUP-
 POWER   STEERING
 PUMP   DISCHARGE   PLY FITTING
            FITTING

19 - 10        STEERING                                                                                                                      PL


                                               POWER STEERING PUMP

                                                                      INDEX
                                                                  page                                                                      page

DESCRIPTION AND OPERATION                                                    POWER STEERING FLUID RESERVOIR . . . .                         . 22
  POWER STEERING PUMP . . . . . . . . . . . . . . .                   10     POWER STEERING FLUID RETURN HOSE . .                           . 16
DIAGNOSIS AND TESTING                                                        POWER STEERING FLUID SUPPLY HOSE
  POWER STEERING SYSTEM TEST                                                  RESERVOIR TO POWER STEERING PUMP                              . 18
   PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . .          11     POWER STEERING PRESSURE SWITCH . . .                           . 13
SERVICE PROCEDURES                                                           POWER STEERING PUMP (ALL ENGINES) . .                          . 19
  POWER STEERING PUMP FLOW CONTROL                                         DISASSEMBLY AND ASSEMBLY
   VALVE SEAL . . . . . . . . . . . . . . . . . . . . . . . . .       12     POWER STEERING PUMP DRIVE PULLEY . .                           . 23
  POWER STEERING PUMP INITIAL OPERATION                                      POWER STEERING PUMP MOUNTING
 ......................................                               12      BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . .   . 24
  POWER STEERING PUMP SUCTION PORT                                         SPECIFICATIONS
   SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   13     POWER STEERING PUMP FASTENER
  POWER STEERING SYSTEM FLUID LEVEL                                           TORQUE SPECIFICATIONS . . . . . . . . . . . .                 . 26
   CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    12     POWER STEERING PUMP FLOW
REMOVAL AND INSTALLATION                                                      SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .        . 25
  POWER STEERING FLUID PRESSURE                                            SPECIAL TOOLS
   HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   14     POWER STEERING PUMP . . . . . . . . . . . . . .                . 26

DESCRIPTION AND OPERATION                                                     All vehicles equipped with power steering use a
                                                                           remote mounted reservoir for the power steering
POWER STEERING PUMP                                                        fluid. The power steering fluid remote reservoir is
  On all vehicles equipped with power steering, the                        mounted to the rear of the cylinder head on the pas-
hydraulic pressure for operation of the power steer-                       senger side of the vehicle.
ing gear is provided by a belt driven power steering                          The service procedures for the TTA power steering
pump (Fig. 1). The TTA power steering pump is a                            pump are limited to the areas and components listed
constant flow rate and displacement, vane type                             below. No repair procedures are to be done on
pump.                                                                      internal components of the TTA power steering
                                                                           pumps.
                                                                              



◦ Jabse Service Manual Search 2023 ◦ Jabse PravopisonTap.bg ◦ Other service manual resources online : FixyaeServiceinfo