Chrysler Neon 1995-1999 Repair Guide

Power Steering Pump

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6 and 7

The power steering pump replacement procedures are the same for both engine applications covered by this guide. The front power steering pump bracket must be removed as an assembly with the power steering pump and removed from the pump after removing the pulley from the pump.


CAUTION
Power steering fluid, engine components and/or the exhaust system may be extremely hot if the engine has been running. NEVER start the engine with any loose or disconnected hoses, or allow the hoses to touch a hot exhaust manifold or catalyst.

  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Remove the banjo bolt and power steering fluid pressure hose from the fitting on the power steering pump.
  4.  



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Fig. Fig. 1: Location of the banjo bolt which must be removed from the fitting on the pump

  1. Discard all used O-rings from the power steering pressure hose banjo fitting and bolt.
  2.  
  3. Remove the hose clamp attaching the power steering fluid supply hose to the power steering pump suction fitting. Remove the power steering fluid supply hose from the power steering pump fitting.
  4.  



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Fig. Fig. 2: Disconnect the fluid supply hose from the power steering pump

  1. For Dual Overhead Cam (DOHC) engines, perform the following:
    1. Raise and safely support the vehicle.
    2.  

  2.  

If equipped with a dual overhead cam engine, the bolt attaching the coolant tube to the intake manifold must be removed.

  1. Remove the bolt attaching the coolant tube to the bottom of the intake manifold. The bolt requires removal in order to allow the coolant tube to be positioned aside for access to the power steering pump mounting bolt. The coolant tube does not need to be removed or the system drained.
  2.  



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Fig. Fig. 3: On DOHC engines, you must unfasten the coolant tube bolt and position the tube aside

  1. Remove the 2 power steering pump-to-cast bracket mounting and adjustment bolts.
  2.  



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Fig. Fig. 4: Location the of the power steering pump mounting bolts as seen from the rear

The power steering pump front mounting bracket is slotted at the bolt securing it to the front engine mount. This bolt only has to be loosened to remove the bracket.

  1. Loosen the bolt attaching the power steering pump front mounting bracket to the front engine mount. Only loosen the bolt enough to slide the bracket out from under the bolt.
  2.  



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Fig. Fig. 5: Loosen the front mounting bracket bolt enough to remove the bracket

  1. Remove the power steering pump drive belt from the pump pulley.
  2.  
  3. Remove the power steering pump and front mounting bracket from the engine as an assembly.
  4.  



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Fig. Fig. 6: The power steering pump and bracket are removed as an assembly

  1. If installed a new pump, transfer the necessary parts from the old pump to the new pump.
  2.  

To install:
  1. Install the power steering pump and bracket onto the engine.
  2.  
  3. Slide the front power steering pump bracket between the bracket mounting bolt and the front engine mount. Make sure the washer on the bolt is between the head of the bolt and bracket and does not get trapped between the bracket and engine mount.
  4.  
  5. Install the 2 pump-to-cast mounting bracket mounting bolts, but do not tighten the bolts yet.
  6.  
  7. Install the power steering belt on the pulley.
  8.  
  9. Place a 1 / 2 in. breaker bar into the square hole in the front power steering pump mounting bracket. Then rotate the pump in to get the proper drive belt tension. For more information, please refer to General Information & Maintenance of this guide. When the proper tension is obtained, tighten the 2 bolts at the pump case mounting bracket to 40 ft. lbs. (54 Nm). Then, tighten the front power steering pump mounting bracket bolt to 40 ft. lbs. (54 Nm).
  10.  



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Fig. Fig. 7: You must set the power steering belt to the proper tension

  1. Attach the power steering supply hose to the pump suction fitting. Install the hose clamp, making sure the clamp is installed on the hose past the upset bead on the power steering pump tube.
  2.  
  3. Using a lint-free towel, wipe all of the open power steering hose ends and pump fittings clean.
  4.  
  5. Install a new O-ring on the end of the power steering pressure hose banjo fitting. Place a new O-ring on the pressure hose banjo fitting bolt.
  6.  
  7. Lubricate both O-rings using fresh, clean power steering fluid.
  8.  
  9. Install the banjo bolt into the pressure hose fitting.
  10.  
  11. Attach the power steering pressure hose on the outlet fitting of the power steering pump.
  12.  
  13. Place the locating pin on the banjo fitting so it is against the pump mounting bracket. While holding the locating pin against the power steering pump bracket, tighten the pump end banjo bolt to 25 ft. lbs. (34 Nm).
  14.  


WARNING
When filling and bleeding the power steering system, always use the proper type of fluid (Mopar® Power Steering Fluid or equivalent). NEVER substitute automatic transmission fluid for the specified fluid.

  1. Fill the power steering pump fluid reservoir with the proper type and amount of fluid.
  2.  
  3. Connect the negative battery cable.
  4.  
  5. Bleed the power steering system, as outlined later in this section.
  6.  

BLEEDING



  1. Fill the power steering pump fluid reservoir with the proper type and amount of fluid.
  2.  
  3. Connect the negative battery cable.
  4.  
  5. Start the engine and let it run for a few minutes, then turn it OFF .
  6.  
  7. Check the reservoir and add fluid to the reservoir if necessary.
  8.  
  9. Repeat the preceding 2 steps until the fluid level stays constant after running the engine.
  10.  
  11. Raise the vehicle's front wheels off the ground and support the front of the vehicle securely with jackstands.
  12.  
  13. Start the engine, then slowly turn the steering wheel right and left a few times, until lightly contacting the wheel stops. Then turn the engine OFF .
  14.  
  15. Add power steering fluid to the reservoir if necessary.
  16.  
  17. Carefully lower the vehicle. Start the engine again and turn the steering wheel from lock-to-lock.
  18.  
  19. Turn the engine OFF . Check the fluid level and add if necessary. If the fluid is very foamy, let the vehicle stand for a few minutes, then repeat the procedure.
  20.  

 
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