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Dodge Neon 2001 Service Manual

Dodge Neon 2001 Service Manual

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Service manual (274 pages)

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GROUP TAB LOCATOR

INs

Introduction

0s

Lubrication & Maintenance

5s

Brakes

6s

Clutch

7s

Cooling

8Ns

Power Systems

8Os

Restraints

8W

Wiring

9s

Engine

21s

Transaxle

23s

Body

Service Manual Comment Forms

(Rear of Manual)

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Summary of Contents for Dodge Neon 2001

Page 1 GROUP TAB LOCATOR Introduction Lubrication & Maintenance Brakes Clutch Cooling Power Systems Restraints Wiring Engine Transaxle Body Service Manual Comment Forms (Rear of Manual)
Page 2 2001 NEON INTRODUCTION INTRODUCTION TABLE OF CONTENTS page page E-MARK LABEL TORQUE REFERENCES DESCRIPTION ......1 DESCRIPTION .
Page 3 2001 NEON INTRODUCTION VEHICLE IDENTIFICATION NUMBER (Continued) VIN CHECK DIGIT To protect the consumer from theft and possible fraud the manufacturer is required to include a check digit at the ninth position of the VIN. The check digit is used by the manufacturer and government agen- cies to verify the authenticity of the vehicle and offi- cial documentation.
Page 4 2001 NEON INTRODUCTION TORQUE REFERENCES tions Chart for torque references not listed in the individual torque charts. DESCRIPTION Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifica- TORQUE SPECIFICATIONS...
Page 5 2001 NEON...
Page 6 2001 NEON LUBRICATION & MAINTENANCE 0s - 1 LUBRICATION & MAINTENANCE TABLE OF CONTENTS page page LUBRICATION & MAINTENANCE FLUID CAPACITIES DESCRIPTION ......1 SPECIFICATIONS .
Page 7 2001 NEON 0s - 2 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) NOTE: For fluid level checking procedures, (Refer Light spark knock at low engine speeds is not to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - harmful to your engine. However, continued heavy 31TH/FLUID - STANDARD PROCEDURE). spark knock at high speeds can cause damage and immediate service is required.
Page 8 2001 NEON LUBRICATION & MAINTENANCE 0s - 3 FLUID TYPES (Continued) levels higher than allowed in the United States. overheat. If you notice a pungent burning odor or MMT is prohibited in Federal and California refor- some light smoke, your engine may be out of tune or mulated gasoline.
Page 9 2001 NEON 0s - 4 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) SAE VISCOSITY OPERATION - ENGINE COOLANT An SAE viscosity grade is used to specify the vis- The cooling system is designed around the coolant. cosity of engine oil. Use only engine oils with multi- The coolant must accept heat from engine metal, in ple viscosities such as 5W-30 or 10W-30.
Page 10 2001 NEON LUBRICATION & MAINTENANCE 0s - 5 MAINTENANCE SCHEDULES performance and reliability. More frequent mainte- nance may be needed for vehicles in severe operating conditions such as dusty areas and very short trip DESCRIPTION driving. There are two maintenance schedules that show proper service for your vehicle.
Page 11 2001 NEON 0s - 6 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) • Replace the engine air cleaner element (fil- SCHEDULE – B ter). • Replace the ignition cables. 3,000 Miles (5 000 km) • Replace the spark plugs. • Change the engine oil. •...
Page 12 2001 NEON LUBRICATION & MAINTENANCE 0s - 7 MAINTENANCE SCHEDULES (Continued) • Change the automatic transaxle fluid/filter and 33,000 Miles (53 000 km) • Change the engine oil. adjust bands. • Replace the engine oil filter. 63,000 Miles (101 000 km) •...
Page 13 2001 NEON 0s - 8 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) • Replace the engine oil filter. 93,000 Miles (149 000 km) • Inspect the engine air cleaner element (fil- • Change the engine oil. • Replace the engine oil filter. ter) and replace as necessary.* This maintenance...
Page 14 2001 NEON BRAKES 5s - 1 BRAKES TABLE OF CONTENTS page page BRAKES-BASE ......1 BRAKES-ABS .
Page 15 2001 NEON 5s - 2 BRAKES-BASE BRAKES-BASE (Continued) DIAGNOSIS AND TESTING - BASE BRAKE LAMP, BRAKE NOISE and OTHER BRAKE CONDI- TIONS. SYSTEM DIAGNOSIS CHARTS NOTE: There are three diagnosis charts following that cover the RED BRAKE WARNING INDICATOR RED BRAKE WARNING INDICATOR LAMP CONDITION POSSIBLE CAUSES CORRECTION...
Page 16 2001 NEON BRAKES-BASE 5s - 3 BRAKES-BASE (Continued) CONDITION POSSIBLE CAUSES CORRECTION DRUM BRAKE SCRAPING 1. ABS wheel speed sensor or tone 1. Inspect, correct or replace faulty OR WHIRRING wheel. component(s). SCRAPING (METAL-TO- 1. Foreign object interference with 1. Inspect brakes and remove foreign METAL).
Page 17 2001 NEON 5s - 4 BRAKES-BASE BRAKES-BASE (Continued) CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE PEDAL 1. Power brake booster runout 1. Check booster vacuum hose and TRAVEL (PEDAL GOES (vacuum assist). engine tune for adequate vacuum TO FLOOR - CAN’T SKID supply.
Page 18 2001 NEON BRAKES-BASE 5s - 5 BRAKES-BASE (Continued) STANDARD PROCEDURE - BASE BRAKE BLEEDING NOTE: For bleeding the ABS hydraulic system, refer to Antilock Brake System Bleeding in the Antilock Brake System section. CAUTION: Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign mat- ter from dropping into the master cylinder reservoir.
Page 19 2001 NEON 5s - 6 BRAKES-BASE BRAKES-BASE (Continued) MASTER CYLINDER FLUID OUTLET PORTS: Tube Fitting Type SAE 45° Inverted Flare W/ABS - Primary Tube 7/16 in.–24 Nut Thread W/ABS - Secondary 3/8 in.–24 Tube Nut Thread W/O ABS - All Tube 7/16 in.–24 Nut Threads ABS HYDRAULIC CONTROL UNIT:...
Page 20 2001 NEON BRAKES-BASE 5s - 7 BRAKES-BASE (Continued) full mark with DOT 3 brake fluid. Check the entire DESCRIPTION TORQUE brake hydraulic system for evidence of a leak. TIRE AND WHEEL: CAUTION: An abnormal loss of brake fluid in the Wheel Mounting Nut 109–150 N·m (80–110 ft.
Page 21 2001 NEON 5s - 8 BRAKES-BASE BRAKE PADS/SHOES-FRONT (Continued) INSPECTION - DISC BRAKE SHOES TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY Visually inspect brake shoes (pads) for uneven lin- BRUSHING. CLEANING SHOULD BE DONE BY ing wear.
Page 22 2001 NEON BRAKES-BASE 5s - 9 DISC BRAKE CALIPERS- EXCESSIVE CONCENTRATIONS ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. FRONT EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING CLEANING - DISC BRAKE CALIPER UNLESS EQUIPMENT USED IS DESIGNED TO CON- TAIN THE DUST RESIDUE.
Page 23 2001 NEON 5s - 10 BRAKES-BASE FLUID RESERVOIR (Continued) (3) Remove the vehicle wiring harness connector NOTE: The master cylinder does not need to be from brake fluid level switch in master cylinder removed from the power brake booster for removal brake fluid reservoir (Fig.
Page 24 2001 NEON BRAKES-BASE 5s - 11 MASTER CYLINDER-LHD (Continued) NOTE: The master cylinder must be bled before installing it on the vehicle. (1) If removed, install the proportioning valves in their master cylinder ports. The valves are identical, so they can be installed in either master cylinder port going to the rear brakes.
Page 25 2001 NEON 5s - 12 BRAKES-BASE MASTER CYLINDER-RHD (Continued) PEDAL REMOVAL NOTE: Before proceeding with this procedure, (Refer to 5 - BRAKES - WARNING). WITH AUTOMATIC TRANSAXLE (1) Disconnect and isolate the battery negative cable from its post on the battery. (2) Place the steering wheel and tires in the STRAIGHT-AHEAD position.
Page 26 2001 NEON BRAKES-BASE 5s - 13 PEDAL (Continued) (11) Remove the two nuts fastening the brake pedal bracket to the instrument panel support (Fig. 11). (12) Carefully remove the brake pedal assembly by pulling the pedal bracket back toward the instru- ment panel, releasing the bracket from the booster studs.
Page 27 2001 NEON 5s - 14 BRAKES-BASE PEDAL (Continued) (3) Push the power brake booster back into mount- ing position from under the hood. (4) Install the two nuts fastening the brake pedal bracket to the instrument panel support (Fig. 11). Install the nuts all the way, but do not tighten them at this time.
Page 28 2001 NEON BRAKES-BASE 5s - 15 PEDAL (Continued) (2) Install the brake pedal assembly onto the studs extending down from the instrument panel support and power brake booster (Fig. 11). (3) Install the two nuts fastening the brake pedal bracket to the instrument panel support (Fig. 11). Install the nuts all the way, but do not tighten them at this time.
Page 29 2001 NEON 5s - 16 BRAKES-BASE POWER BRAKE BOOSTER-RHD (Continued) (7) Working from underneath instrument (8) Connect the clutch pedal push rod. Slide the panel, disconnect the brake pedal push rod. Remove push rod on the clutch pedal mounted stud until the the retaining clip from the end of the brake pedal plastic retention clip locks it in place.
Page 30 2001 NEON BRAKES-BASE 5s - 17 PROPORTIONING VALVE (Continued) Fig. 16 Proportioning Valve Location Fig. 17 Brake Pedal Holding Tool 1 - RIGHT FRONT BRAKE TUBE 2 - LEFT FRONT BRAKE TUBE 1 - CLUTCH PEDAL (IF EQUIPPED WITH MANUAL TRANSAXLE) 3 - LEFT REAR BRAKE TUBE 2 - THROTTLE PEDAL 4 - REAR PROPORTIONING VALVES...
Page 31 2001 NEON 5s - 18 BRAKES-BASE PROPORTIONING VALVE (Continued) pressure in the system, before reapplying the pedal to reach the target pressure at the inlet gauge. This is necessary to get an accurate reading of the outlet pressure. (10) Once inlet pressure has been achieved, check the pressure reading on the proportioning valve out- let gauge.
Page 32 2001 NEON BRAKES-BASE 5s - 19 PROPORTIONING VALVE (Continued) SHOES-PARKING BRAKE REMOVAL NOTE: Before proceeding with this procedure, (Refer to 5 - BRAKES - WARNING). NOTE: This procedure applies to vehicles with rear disc brakes only. (1) Raise the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCE- DURE).
Page 33 2001 NEON 5s - 20 BRAKES-BASE SHOES-PARKING BRAKE (Continued) (9) Turn the brake shoe adjuster wheel until the (12) Pull the rear brake shoe away from anchor. adjuster is at shortest length. Remove the rear brake shoe and upper return spring (10) Remove the adjuster assembly from the park- (Fig.
Page 34 2001 NEON BRAKES-BASE 5s - 21 SHOES-PARKING BRAKE (Continued) (10) Install the rear brake rotor (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS INSTALLATION). (11) Install rear disc brake caliper (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES - INSTALLATION). (12) Install the tire and wheel assembly (Refer to 22 - TIRES/WHEELS - INSTALLATION).
Page 35 2001 NEON 5s - 22 BRAKES-BASE CABLES-PARKING BRAKE (Continued) Fig. 28 Compressing Cable Retainer Fig. 29 Rear Disc Brakes 1 - CARPET ROLLED FORWARD 1 - DISC BRAKE CALIPER 2 - WRENCH 2 - DISC BRAKE ADAPTER 3 - RIGHT REAR CABLE 3 - GUIDE PIN BOLTS 4 - REAR PARKING BRAKE CABLES 4 - HUB AND BEARING...
Page 36 2001 NEON BRAKES-BASE 5s - 23 CABLES-PARKING BRAKE (Continued) • Remove the parking brake cable from the rear brake support plate. The parking brake cable can be removed from brake support plate using a ½ inch box wrench to compress the locking fingers on the park- ing brake cable retainer (Fig.
Page 37 2001 NEON 5s - 24 BRAKES-BASE CABLES-PARKING BRAKE (Continued) (7) Install the hub and bearing dust cap. (8) On drum brake equipped vehicles, install the rear brake drum. (9) On vehicles equipped with rear disc brakes, install the brake rotor, then the disc brake caliper (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ ROTORS - INSTALLATION) (Fig.
Page 38 2001 NEON BRAKES-BASE 5s - 25 LEVER-PARKING BRAKE REMOVAL WARNING: THE AUTOMATIC ADJUSTING FEATURE OF THIS PARKING BRAKE LEVER CONTAINS A CLOCK SPRING LOADED TO APPROXIMATELY 25 POUNDS. DO NOT RELEASE THE AUTOMATIC ADJUSTER LOCKOUT DEVICE UNLESS THE REAR PARKING BRAKE CABLES AND EQUALIZER ARE CONNECTED TO THE LEVER OUTPUT CABLE.
Page 39 2001 NEON 5s - 26 BRAKES-BASE LEVER-PARKING BRAKE (Continued) (7) Remove the wiring harness electrical connector WARNING: WHEN REPAIRS TO THE PARKING from the parking brake warning lamp switch on the BRAKE LEVER OR CABLES ARE REQUIRED, THE parking brake lever (Fig. 38). AUTOMATIC ADJUSTER MUST BE LOADED AND LOCKED OUT TO AVOID POSSIBLE INJURY.
Page 40 2001 NEON BRAKES-ABS 5s - 27 BRAKES-ABS TABLE OF CONTENTS page page BRAKES-ABS OPERATION......30 DESCRIPTION .
Page 41 2001 NEON 5s - 28 BRAKES-ABS BRAKES-ABS (Continued) TIRE NOISE AND MARKS speed sensor mounting bolts; excessive tone wheel runout; excessively large tone wheel-to-wheel speed Although the ABS system prevents complete wheel sensor air gap, or a damaged speed sensor head face. lockup, some wheel slip is desired in order to achieve Give special attention to these components when optimum braking performance.
Page 42 2001 NEON BRAKES-ABS 5s - 29 BRAKES-ABS (Continued) NOTE: Diagnostic trouble codes (DTCs) are kept in any DTCs are present, refer to the Appropriate Diag- the controller’s memory until either erased by the nostic Information. technician using the DRBIII , or erased automati- cally after 3500 miles or 255 ignition key cycles, SPECIFICATIONS whichever occurrs first.
Page 43 2001 NEON 5s - 30 BRAKES-ABS FRONT WHEEL SPEED SENSOR DESCRIPTION The Mark 20e system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magne- toresistive to help increase performance and durabil- ity.
Page 44 2001 NEON BRAKES-ABS 5s - 31 REAR WHEEL SPEED SENSOR (Continued) SPECIFICATIONS. Each WSS is serviced individu- ally. The tone wheels are serviced as an assembly with the hub and bearing assemblies. Fig. 5 Right Rear Wheel Speed Sensor 1 - RIGHT REAR WHEEL SPEED SENSOR 2 - TENSION STRUT Fig.
Page 45 2001 NEON...
Page 46 2001 NEON CLUTCH 6s - 1 CLUTCH TABLE OF CONTENTS page page CLUTCH MASTER CYLINDER DESCRIPTION ......1 DESCRIPTION .
Page 47 2001 NEON 6s - 2 CLUTCH CLUTCH (Continued) Fig. 3 Clutch Coupling Powerflow - Typical der through a connecting line. In turn, the slave cylinder operates the clutch release fork (Fig. 2). Slave cylinder force causes the release lever to hold the release bearing in contact with the diaphragm Fig.
Page 48 2001 NEON CLUTCH 6s - 3 CLUTCH (Continued) SERVICE DIAGNOSIS - CLUTCH GRAB/CHATTER CONDITION POSSIBLE CAUSES CORRECTION CLUTCH DISC FACING Oil leak at engine rear main or Correct leak and replace modular clutch COVERED WITH OIL OR transaxle input shaft seal. assembly.
Page 49 2001 NEON 6s - 4 CLUTCH CLUTCH (Continued) SERVICE DIAGNOSIS - IMPROPER CLUTCH RELEASE CONDITION POSSIBLE CAUSES CORRECTION CLUTCH DISC BINDS ON Clutch disc hub splines damaged Clean, smooth, and lubricate disc and shaft INPUT SHAFT SPLINES during installation splines. Replace modular clutch assembly, or clutch disc, and/or input shaft if splines are severely damaged.
Page 50 2001 NEON CLUTCH 6s - 5 CLUTCH (Continued) DIAGNOSIS AND TESTING - CLUTCH CHATTER (c) Check linkage for excessive wear on the pivot stud and fork fingers. Replace all worn parts. COMPLAINTS (d) Check clutch assembly for contamination For all clutch chatter complaints, perform the fol- (dirt, oil).
Page 51 2001 NEON 6s - 6 CLUTCH CLUTCH INTERLOCK UPSTOP SWITCH REMOVAL (1) Disconnect and isolate battery negative cable. (2) Remove left lower instrument panel bezel (Fig. Fig. 5 Brake Booster Mounting Nuts and Rod Retaining Clip 1 - CLIP 2 - BOOSTER MOUNTING NUTS 3 - BOOSTER MOUNTING NUTS Fig.
Page 52 2001 NEON CLUTCH 6s - 7 CLUTCH INTERLOCK UPSTOP SWITCH (Continued) Fig. 8 Clutch Master Cylinder Pushrod Adjustment Screw 1 - ADJUSTMENT SCREW RELEASE BEARING AND FORK Fig. 7 Interlock/Upstop Switch DESCRIPTION 1 - UPSTOP SWITCH 2 - INTERLOCK SWITCH A conventional release bearing is used to engage 3 - CLUTCH PEDAL and disengage the clutch pressure plate.
Page 53 2001 NEON 6s - 8 CLUTCH RELEASE BEARING AND FORK (Continued) OPERATION The release bearing is operated by the release fork. Slave cylinder force causes the release lever to move the release bearing into contact with the diaphragm spring. As additional force is applied, the bearing presses the diaphragm spring fingers inward on the fulcrums.
Page 54 2001 NEON CLUTCH 6s - 9 MASTER CYLINDER (Continued) (1) Remove air cleaner assembly (Fig. 12). Fig. 14 Slave Cylinder and Hydraulic Supply Tube 1 - SLAVE CYLINDER 2 - HYDRAULIC TUBE Fig. 12 Air Cleaner Assembly Removal/Installation (5) Remove hydraulic hose from left rail retainer 1 - AIR CLEANER ASSY.
Page 55 2001 NEON 6s - 10 CLUTCH MASTER CYLINDER (Continued) Fig. 16 Brake Booster Mounting Nuts 1 - CLIP 2 - BOOSTER MOUNTING NUTS 3 - BOOSTER MOUNTING NUTS Fig. 17 Clutch Master Cylinder Removal/Installation (13) Disconnect clutch master cylinder rod from 1 - RESERVOIR 2 - MASTER CYLINDER clutch pedal.
Page 56 2001 NEON CLUTCH 6s - 11 MASTER CYLINDER (Continued) (11) Install the ABS module/purge solenoid, PDC, and air cleaner. (12) Depress and release the clutch pedal a mini- mum of ten (10) times to allow any residual air in the system to be vented to the reservoir. (13) Connect the negative battery cable.
Page 57 2001 NEON 6s - 12 CLUTCH MODULAR CLUTCH (Continued) (10) Disconnect the vehicle speed sensor connector (Fig. 24). Fig. 22 Disconnect Hydraulic Circuit Using Tool 6638A 1 - QUICK CONNECT FITTING 2 - TOOL 6638A (8) Remove shift cable-to-bracket clips (Fig. 23). (9) Disconnect shift selector and crossover cable from levers (Fig.
Page 58 2001 NEON CLUTCH 6s - 13 MODULAR CLUTCH (Continued) Fig. 27 Starter Motor Removal/Installation - Typical 1 - BOLT 2 - GROUND 3 - STARTER Fig. 25 Left Lateral Bending Brace and Structural 4 - BOLT Collar - Typical 1 - LATERAL BENDING BRACE (21) Remove transaxle upper mount thru-bolt.
Page 59 2001 NEON 6s - 14 CLUTCH MODULAR CLUTCH (Continued) (22) Carefully lower engine and transaxle on screw (7) Install starter motor and tighten bolts to 54 jack until proper removal clearance is obtained. N·m (40 ft. lbs.) torque. Make sure to fasten ground (23) Obtain a helper to assist in holding transaxle cable to upper starter bolt as shown in (Fig.
Page 60 2001 NEON CLUTCH 6s - 15 MODULAR CLUTCH (Continued) (17) Connect shift crossover and selector cables to shift lever. Install cables to bracket and install retaining clips (Fig. 23). (18) Connect the master cylinder hydraulic line to the slave cylinder hydraulic line. An audible click should be heard.
Page 61 2001 NEON 6s - 16 CLUTCH SLAVE CYLINDER (Continued) REMOVAL NOTE: Replacement slave cylinder assemblies come pre-filled with fluid. No fluid service or sys- tem bleeding should be required. (1) Raise vehicle on hoist. (2) Disconnect clutch hydraulic quick connect using tool 6638A (Fig.
Page 62 2001 NEON COOLING 7s - 1 COOLING TABLE OF CONTENTS page page COOLING ACCESSORY DRIVE ..... . . 3 DESCRIPTION ......1 ENGINE .
Page 63 2001 NEON 7s - 2 COOLING COOLING (Continued) SPECIAL TOOLS COOLING SYSTEM DRB III with PEP Module – OT-CH6010A Cooling System Tester – 7700 Coolant Refractometer – 8286 Belt Tension Gauge Adapter – 8371...
Page 64 2001 NEON ACCESSORY DRIVE 7s - 3 ACCESSORY DRIVE TABLE OF CONTENTS page page DRIVE BELTS REMOVAL ....... 3 INSTALLATION.
Page 65 2001 NEON 7s - 4 ACCESSORY DRIVE DRIVE BELTS (Continued) Fig. 2 Power Steering / A/C Belt 1 - BELT 6 - P/S PULLEY 2 - P/S PULLEY 7 - TENSIONER PULLEY 3 - TENSIONER PULLEY 8 - A/C PULLEY 4 - CRANKSHAFT PULLEY 9 - CRANKSHAFT PULLEY 5 - BELT...
Page 66 2001 NEON ACCESSORY DRIVE 7s - 5 DRIVE BELTS (Continued) Fig. 5 Belt Center Spans DRIVE BELT TENSION CHART Accessory Belt Tension Drive Belt Power Steering Pump & A/C Dynamic Tensioned Compressor 135 lbs. 224 – 252 Generator Used* 70 lbs. 172 –...
Page 67 2001 NEON 7s - 6 ENGINE ENGINE TABLE OF CONTENTS page page COOLANT INSTALLATION......6 DESCRIPTION .
Page 68 2001 NEON ENGINE 7s - 7 HEATER SUPPLY/RETURN TUBES (Continued) (7) Connect two heater hoses to heater tubes near (5) Remove the powertrain control module (PCM) battery. Ensure clamps are positioned properly to with bracket (Refer to 8 - ELECTRICAL/ELEC- seal hoses and avoid contact with engine components.
Page 69 2001 NEON 7s - 8 ENGINE RADIATOR FAN (Continued) INSTALLATION - DUAL RADIATOR FAN (4 SPEED AUTOMATIC TRANSMISSION EQUIPPED VEHICLES) (1) Install radiator fan assembly by lowering into position on radiator. Ensure the fan assembly lower mounts (Fig. 4) are engaged properly into slots on radiator’s lower tank.
Page 70 2001 NEON TRANSMISSION 7s - 9 TRANSMISSION TABLE OF CONTENTS page page TRANSMISSION STANDARD PROCEDURE ....10 DIAGNOSIS AND TESTING ....9 FLUSHING COOLERS AND TUBES .
Page 71 2001 NEON 7s - 10 TRANSMISSION TRANSMISSION (Continued) (d) If an oil cooler restriction is suspected, per- equivalent solution conforming to MS-552. Flushing form further inspections and flow meter testing by solvents are petroleum based solutions generally isolating components (i.e. lines, coolers). used to clean automatic transmission components.
Page 72 2001 NEON POWER SYSTEMS 8Ns - 1 POWER SYSTEMS TABLE OF CONTENTS page page POWER SYSTEMS ......1 POWER MIRRORS .
Page 73 2001 NEON 8Ns - 2 POWER LOCKS POWER LOCKS TABLE OF CONTENTS page page POWER LOCKS KEYLESS ENTRY TRANSMITTER DESCRIPTION ......2 DESCRIPTION .
Page 74 2001 NEON POWER LOCKS 8Ns - 3 POWER LOCKS (Continued) module will allow the power door locks to lock via the storage in the dealer lot. Dealer lot storage mode pro- interior door lock switches. vides limited VTSS and power door lock functions, but disables the Remote Keyless Entry (RKE) func- CENTRAL LOCKING/UNLOCKING tions.
Page 75 2001 NEON 8Ns - 4 POWER LOCKS POWER LOCKS (Continued) vides limited VTSS and power door lock functions, but disables the Remote Keyless Entry (RKE) func- tions. This mode is intended to be used when the vehicle is on the dealer lot to provide VTSS coverage of the vehicle while minimizing battery drain.
Page 76 2001 NEON POWER LOCKS 8Ns - 5 OPERATION KEYLESS ENTRY The transmitter has four buttons for operation. TRANSMITTER They are LOCK, UNLOCK, DECK LID RELEASE, and PANIC. DESCRIPTION • The UNLOCK button will unlock the driver’s door and enable illuminated entry. Pushing and releasing the button once will unlock the driver’s door.
Page 77 2001 NEON 8Ns - 6 POWER LOCKS REMOTE KEYLESS ENTRY MODULE REMOVAL (1) Disconnect and isolate the battery negative cable (Fig. 1). (2) Remove the instrument panel top cover. Refer to Body, Instrument Panel, Instrument Pane Top Cover, Removal. (3) Remove the two screws holding the RKE mod- ule to the instrument panel assembly (Fig.
Page 78 2001 NEON POWER MIRRORS 8Ns - 7 POWER MIRRORS TABLE OF CONTENTS page page POWER FOLDAWAY MIRROR OPERATION ......8 DIAGNOSIS AND TESTING .
Page 79 2001 NEON 8Ns - 8 POWER MIRRORS POWER FOLDAWAY MIRROR SWITCH DESCRIPTION Some vehicles are equipped with Power Fold-Away Side View Mirrors. This feature allows both the driver and passenger side view mirrors to fold inward (retract) on demand. This feature is con- trolled by a additional switch located on the power mirror switch.
Page 80 2001 NEON POWER MIRRORS 8Ns - 9 POWER FOLDAWAY MIRROR SWITCH (Continued) RETRACTED MIRROR SWITCH CIRCUIT TEST (3) Disconnect wire connector from switch. (4) Remove two switch retaining screws (Fig. 4). NOTE: MIRROR POSITION SWITCH MUST BE IN THE “FOLD” POSITION TO USE CHART BELOW. WOBBLE LEFT MIRROR RIGHT...
Page 81 2001 NEON...
Page 82 2001 NEON RESTRAINTS 8Os - 1 RESTRAINTS TABLE OF CONTENTS page page 8OS-RESTRAINTS-SUPPLEMENT FRONT SEAT BELT & RETRACTOR DESCRIPTION ......1 REMOVAL .
Page 83 2001 NEON 8Os - 2 RESTRAINTS 8OS-RESTRAINTS-SUPPLEMENT (Continued) sor and software contained within the Airbag Control (2) If the airbag warning lamp lights but fails to Module (ACM). The ACM also contains an impact go out after ten seconds, test the system using a sensor and a safing sensor, which are monitored by DRB lll scan tool and the proper Body Diagnostic...
Page 84 2001 NEON RESTRAINTS 8Os - 3 DRIVER AIRBAG (Continued) The protective trim cover is fitted to the front of deploying the airbag. The SIACM communicates with the airbag and forms a decorative cover in the center the Airbag Control Module (ACM) via the PCI bus of the steering wheel.
Page 85 2001 NEON 8Os - 4 RESTRAINTS SIDE IMPACT AIRBAG CONTROL MOD (Continued) CHILD TETHER DESCRIPTION The Child Tether Assembly (Fig. 4) consists of the Child Tether Anchor and the Child Tether Assembly Caps. The Child Tether Anchor (Fig. 5) is not service- able.
Page 86 2001 NEON RESTRAINTS 8Os - 5 CHILD TETHER (Continued) (4) Remove seat belt retractor from vehicle. Fig. 6 CHILD TETHER ASSEMBLY CAP 1 - CHILD TETHER ASSEMBLY CAP AND COVER Fig. 8 FRONT SEAT BELT RETRACTOR 1 - FRONT SEAT BELT ADJUSTER 2 - UPPER B-PILLAR TRIM PANEL 3 - ADJUSTER BUTTON 4 - TURNING LOOP...
Page 87 2001 NEON 8Os - 6 RESTRAINTS PASSENGER AIRBAG (Continued) (4) Remove three screws to glove box door and remove door from instrument panel. (5) Remove three passenger airbag cover screws attaching cover to top of instrument panel (Fig. 10). (6) Remove two passenger airbag cover screws attaching cover to front lower instrument panel.
Page 88 2001 NEON RESTRAINTS 8Os - 7 PASSENGER AIRBAG (Continued) Fig. 10 PASSENGER AIRBAG REMOVE/INSTALL CLOCKSPRING REMOVAL (1) Place the front road wheels in the straight ahead position then: • Rotate the steering wheel half turn (180 degrees) to the right (clockwise). •...
Page 89 2001 NEON 8Os - 8 RESTRAINTS CLOCKSPRING (Continued) speed control leads through the larger slot. Ensure leads do not get pinched under the steering wheel. (6) Route speed control wires under and behind the airbag module mounting tabs. (7) Connect the horn lead wire and the airbag lead wire to the airbag module.
Page 90 2001 NEON RESTRAINTS 8Os - 9 SEAT AIRBAG (Continued) cushion. Upon deployment, the seat back trim cover will tear open and allow the seat airbag to fully deploy between the seat and the door. REMOVAL (1) Position the left front seat in the full forward position.
Page 91 2001 NEON 8Os - 10 RESTRAINTS SEAT AIRBAG (Continued) INSTALLATION mounting location of the back cover. Refer to Body for a detailed procedure. (7) Install the front seat back in vehicle. Refer to NOTE: The seat airbag connector must face down Body, Seats, Front Seat, Installation.
Page 92 2001 NEON RESTRAINTS 8Os - 11 SHOULDER BELT HEIGHT ADJUSTER (Continued) INSTALLATION (1) Place into position the shoulder belt adjuster. (2) Install bolts attaching shoulder belt adjuster to B-pillar. Tighten all seat belt bolts to 40 N·m (30 ft. CAUTION: Front seat belt assemblies must be lbs.) torque.
Page 93 2001 NEON...
Page 94 2001 NEON WIRING 8Wa - 1 WIRING TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION..8Wa-01-1 INTERIOR LIGHTING....8Wa-44-1 COMPONENT INDEX .
Page 95 2001 NEON...
Page 96 2001 NEON 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 1 8W-01 WIRING DIAGRAM INFORMATION TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION CONNECTOR - MOLEX DESCRIPTION ......1 REMOVAL .
Page 97 2001 NEON 8Wa - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 1 WIRING DIAGRAM EXAMPLE 1...
Page 98 2001 NEON 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 3 WIRING DIAGRAM INFORMATION (Continued) Fig. 2 WIRING DIAGRAM EXAMPLE 2...
Page 99 2001 NEON 8Wa - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 3 WIRING DIAGRAM SYMBOLS...
Page 100 2001 NEON 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 5 WIRING DIAGRAM INFORMATION (Continued) TERMINOLOGY TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA- LYTIC CONVERTER AND MUFFLER. This is a list of terms and definitions used in the wiring diagrams. WARNING: DO NOT ALLOW FLAME OR SPARKS LHD .
Page 101 2001 NEON 8Wa - 01 - 6 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) • Probing Tools - These tools are used for probing diagnosis. If the vehicle is equipped with these items, terminals in connectors (Fig. 4)Select the proper size disconnect them to verify these add-on items are not tool from Special Tool Package 6807, and insert it the cause of the problem.
Page 102 2001 NEON 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 7 WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING FOR STANDARD PROCEDURE - TESTING FOR CONTINUITY SHORT TO GROUND ON FUSES POWERING (1) Remove the fuse for the circuit being checked SEVERAL LOADS or, disconnect the battery.
Page 103 2001 NEON 8Wa - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION SPECIAL TOOLS CONNECTOR - AUGAT SPECIAL TOOLS - WIRING/TERMINAL REMOVAL (1) Disconnect battery. (2) Disconnect the connector from its mating half/ component. (3) Push down on the yellow connector locking tab to release the terminals (Fig.
Page 104 2001 NEON 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 9 CONNECTOR - AUGAT (Continued) INSTALLATION (1) Reset the terminal locking tang. (2) Insert the removed wire in the same cavity on the repair connector. (3) Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities.
Page 105 2001 NEON 8Wa - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION CONNECTOR - THOMAS AND BETTS (Continued) (4) Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). Fig. 14 SINGLE LOCK TAB 1 - SINGLE LOCK TAB Fig.
Page 106 2001 NEON 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 11 TERMINAL REMOVAL (1) Disconnect battery. (2) Disconnect the connector being repaired from its mating half/component. (3) Remove connector locking wedge, required (Fig. 16). Fig. 18 TERMINAL REMOVAL USING SPECIAL TOOL 1 - FROM SPECIAL TOOL KIT 6680 2 - CONNECTOR (5) Cut the wire 6 inches from the back of the con-...
Page 107 2001 NEON 8Wa - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION WIRE STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the cor- rect gage be used as shown in the wiring diagrams. (1) Remove one-half (1/2) inch of insulation from each wire that needs to be spliced.
Page 108 2001 NEON 8W-02 COMPONENT INDEX 8Wa - 02 - 1 8W-02 COMPONENT INDEX Component Page Component Page A/C Compressor Clutch Relay ... 8Wa-42 Fuses (FB) ......8Wa-11 A/C Compressor Clutch .
Page 109 2001 NEON 8Wa - 02 - 2 8W-02 COMPONENT INDEX Component Page Component Page Side Impact Airbag Control Module ..8Wa-43 Traction Control Switch ....8Wa-35 Side Marker Lamps .
Page 110 2001 NEON 8W-10 POWER DISTRIBUTION 8Wa - 10 - 1 8W-10 POWER DISTRIBUTION Component Page Component Page A/C Compressor Clutch Relay ..8Wa-10-7, 18 Fuse 17 (PDC) ....8Wa-10-7, 14 A/C Compressor Clutch .
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Page 132 2001 NEON 8W-11 FUSE BLOCK 8Wa - 11 - 1 8W-11 FUSE BLOCK Component Page Component Page A/C Compressor Clutch Relay ..8Wa-11-11, 12 Left Lavalier Module ... . . 8Wa-11-15, 20 A/C Cycling Switch .
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Page 154 2001 NEON 8W-15 GROUND DISTRIBUTION 8Wa - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8Wa-15-5 Left Rear Fog Lamp ....8Wa-15-16 A/C-Heater Control .
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Page 172 2001 NEON 8W-18 BUS COMMUNICATIONS 8Wa - 18 - 1 8W-18 BUS COMMUNICATIONS Component Page Component Page Airbag Control Module ....8Wa-18-3 Power Distribution Center ... . 8Wa-18-2 Controller Antilock Brake .
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Page 176 2001 NEON 8W-20 CHARGING SYSTEM 8Wa - 20 - 1 8W-20 CHARGING SYSTEM Component Page Component Page Automatic Shut Down Relay ... 8Wa-20-2 G105 ......8Wa-20-2 Battery .
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Page 180 2001 NEON 8W-21 STARTING SYSTEM 8Wa - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Battery ......8Wa-21-2 Generator .
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Page 182 2001 NEON 8W-30 FUEL/IGNITION SYSTEM 8Wa - 30 - 1 8W-30 FUEL/IGNITION SYSTEM Component Page Component Page A/C Compressor Clutch Relay ..8Wa-30-9, 24 G103 ..... . 8Wa-30-13, 27, 29 A/C High Pressure Switch .
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Page 216 2001 NEON 8W-31 TRANSMISSION CONTROL SYSTEM 8Wa - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Component Page Component Page Data Link Connector ....8Wa-31-9 Output Speed Sensor .
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Page 226 2001 NEON 8W-33 VEHICLE SPEED CONTROL 8Wa - 33 - 1 8W-33 VEHICLE SPEED CONTROL Component Page Component Page Brake Lamp Switch ....8Wa-33-3 G201 .
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Page 230 2001 NEON 8W-35 ANTILOCK BRAKES 8Wa - 35 - 1 8W-35 ANTILOCK BRAKES Component Page Component Page Brake Lamp Switch ....8Wa-35-2 G102 ......8Wa-35-2 Controller Antilock Brake .
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Page 234 2001 NEON 8W-39 VEHICLE THEFT SECURITY SYSTEM 8Wa - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM Component Page Component Page Data Link Connector ... 8Wa-39-3, 12, 13 Left Lavalier Module ....8Wa-39-10 Decklid Release Switch .
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Page 250 2001 NEON 8W-40 INSTRUMENT CLUSTER 8Wa - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Component Page A/C-Heater Control ....8Wa-40-15 Left Front Fog Lamp ... . . 8Wa-40-18, 20 Airbag Control Module .
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Page 270 2001 NEON 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8Wa - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET Component Page Component Page Cigar Lighter/Power Outlet ... . 8Wa-41-4 Horn Relay ..... . 8Wa-41-2, 3 Clockspring .
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Page 274 2001 NEON 8W-42 AIR CONDITIONING-HEATER 8Wa - 42 - 1 8W-42 AIR CONDITIONING-HEATER Component Page Component Page A/C Compressor Clutch Relay ..8Wa-42-2 Fuse 11 (FB) ..... 8Wa-42-2, 5 A/C Compressor Clutch .
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Page 280 2001 NEON 8W-43 AIRBAG SYSTEM 8Wa - 43 - 1 8W-43 AIRBAG SYSTEM Component Page Component Page Airbag Control Module ... 8Wa-43-2, 3, 4 Fuse 12 (FB) ..... 8Wa-43-3, 5 Clockspring .
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Page 286 2001 NEON 8W-44 INTERIOR LIGHTING 8Wa - 44 - 1 8W-44 INTERIOR LIGHTING Component Page Component Page A/C-Heater Control ....8Wa-44-5 Headlamp Leveling Switch ... . 8Wa-44-5 Cargo Lamp .
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Page 292 2001 NEON 8W-47 AUDIO SYSTEM 8Wa - 47 - 1 8W-47 AUDIO SYSTEM Component Page Component Page Antenna ......8Wa-47-5 Left Front Door Speaker .
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Page 298 2001 NEON 8W-48 REAR WINDOW DEFOGGER 8Wa - 48 - 1 8W-48 REAR WINDOW DEFOGGER Component Page Component Page Fuse 6 (FB) ......8Wa-48-2 G301 .
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Page 300 2001 NEON 8W-50 FRONT LIGHTING 8Wa - 50 - 1 8W-50 FRONT LIGHTING Component Page Component Page Circuit Breaker No. 2 (FB) ..8Wa-50-2, 4 Instrument Cluster ..8Wa-50-2, 4, 8, 10, 11, 12 Fuse 10 (FB) .
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Page 314 2001 NEON 8W-51 REAR LIGHTING 8Wa - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Back-Up Lamp Switch ....8Wa-51-2 Left License Lamp ....8Wa-51-6 Brake Lamp Switch .
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Page 322 2001 NEON 8W-52 TURN SIGNALS 8Wa - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page Brake Lamp Switch ....8Wa-52-2 Left Front Turn Signal Lamp ..8Wa-52-6 Controller Antilock Brake .
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Page 332 2001 NEON 8W-53 WIPERS 8Wa - 53 - 1 8W-53 WIPERS Component Page Component Page Fuse 4 (FB) ..... . 8Wa-53-2, 3 G204 .
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Page 336 2001 NEON 8W-60 POWER WINDOWS 8Wa - 60 - 1 8W-60 POWER WINDOWS Component Page Component Page Circuit Breaker No. 1 (FB) ..8Wa-60-2, 3, 4, 5, 6 G203 ..... 8Wa-60-2, 3, 4, 5, 6 Driver Power Window Motor .
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Page 342 2001 NEON 8W-61 POWER DOOR LOCKS 8Wa - 61 - 1 8W-61 POWER DOOR LOCKS Component Page Component Page Driver Cylinder Lock Switch ..8Wa-61-3, 4 G204 ......8Wa-61-2 Driver Door Lock Motor/Ajar Switch .
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Page 350 2001 NEON 8W-62 POWER MIRRORS 8Wa - 62 - 1 8W-62 POWER MIRRORS Component Page Component Page Driver Power Mirror ... 8Wa-62-3, 4, 5, 6 G203 ......8Wa-62-2, 3 Fuse 1 (FB) .
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Page 356 2001 NEON 8W-63 POWER SEAT 8Wa - 63 - 1 8W-63 POWER SEAT Component Page Component Page Fuse 13 (FB) ..... . . 8Wa-63-2 Power Seat Motor .
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Page 358 2001 NEON 8W-64 POWER SUNROOF 8Wa - 64 - 1 8W-64 POWER SUNROOF Component Page Component Page Fuse 3 (FB) ..... . 8Wa-64-2, 3 Sunroof Motor .
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Page 362 2001 NEON 8W-70 SPLICE INFORMATION 8Wa - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S102 ......8Wa-11-19 S212 .
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Page 366 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 1 8W-80 CONNECTOR PINOUTS Component Page Component Page A/C Compressor Clutch ....8Wa-80-4 C210 (Built-Up-Export) ....8Wa-80-20 A/C Cycling Switch .
Page 367 2001 NEON 8Wa - 80 - 2 8W-80 CONNECTOR PINOUTS Component Page Component Page Fuel Injector No. 4 ....8Wa-80-32 Multi-Function Switch ....8Wa-80-42 Output Speed Sensor (EATX) .
Page 368 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 3 Component Page Component Page Right Rear Turn Signal Lamp Sunroof Motor ..... 8Wa-80-58 (Built-Up-Export) .
Page 369 2001 NEON 8Wa - 80 - 4 8W-80 CONNECTOR PINOUTS A/C COMPRESSOR CLUTCH - BLACK 2 WAY CIRCUIT FUNCTION C3 20DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT Z1 20BK GROUND A/C CYCLING SWITCH - BLACK 3 WAY CIRCUIT FUNCTION C21 22DB/OR A/C SWITCH SENSE F20 22WT FUSED IGNITION SWITCH OUTPUT (RUN)
Page 370 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 5 A/C-HEATER CONTROL - GRAY 7 WAY CIRCUIT FUNCTION Z8 14BK/VT GROUND C7 14BK/TN BLOWER MOTOR HIGH DRIVER C6 14LB BLOWER MOTOR M2 DRIVER C5 14LG BLOWER MOTOR M1 DRIVER C4 14TN BLOWER MOTOR LOW DRIVER C2 22DB/YL MODE SWITCH OUTPUT...
Page 371 2001 NEON 8Wa - 80 - 6 8W-80 CONNECTOR PINOUTS BACK-UP LAMP SWITCH (MTX) - GRAY 2 WAY CIRCUIT FUNCTION F20 20WT (2.0L) FUSED IGNITION SWITCH OUTPUT (RUN) F20 18WT (1.6L) FUSED IGNITION SWITCH OUTPUT (RUN) L1 18VT/BK BACK-UP LAMP FEED BLOWER MOTOR RESISTOR BLOCK - BLACK 10 WAY CIRCUIT FUNCTION...
Page 372 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 7 BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID - WHITE 2 WAY CIRCUIT FUNCTION K29 20WT/PK BRAKE LAMP SWITCH SENSE F20 20WT FUSED IGNITION SWITCH OUTPUT (RUN) C101 (2.0L) - BLACK (HD/LP & DASH SIDE) CIRCUIT A142 18DG/OR K4 20BK/LB...
Page 373 2001 NEON 8Wa - 80 - 8 8W-80 CONNECTOR PINOUTS C101 (1.6L) - BLACK (HD/LP & DASH SIDE) CIRCUIT V37 20RD/LG G9 20GY/BK K29 20WT/PK K10 20WT K52 20PK/BK K119 20LG/BK T141 20YL/RD C27 18DB/PK C28 18DB/OR K51 18DB/YL K31 18BR D25 20VT/YL D20 20LG D21 20PK...
Page 374 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 9 C102 (2.0L) - LT. GRAY (ENGINE SIDE) CIRCUIT C20 18BR/OR F12 18DB/WT G7 20WT/OR T40 14BR V32 20YL/RD Z1 18BK Z12 18BK/TN K201 20BR/YL (RT PACKAGE) K200 20BR/WT (RT PACKAGE) C102 (1.6L) - LT.
Page 375 2001 NEON 8Wa - 80 - 10 8W-80 CONNECTOR PINOUTS C103 - BLACK (I/P SIDE) CIRCUIT B27 18RD/YL (ABS) G70 18BR/TN L160 18TN/RD L60 20TN (BUILT-UP-EXPORT) M1 20PK A15 18WT L13 18BR/YL (BUILT-UP-EXPORT) K29 20WT/PK L44 12VT/RD L3 16RD/OR L3 16RD/OR A41 14YL A41 14YL (EATX) A1 14RD...
Page 376 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 11 C104 - GRAY (HD/LP & DASH SIDE) CIRCUIT L39 18LB (LHD) (FRONT FOG LAMPS) L39 16LB (RHD) (FRONT FOG LAMPS) C21 20DB/OR L61 20LG (BUILT-UP-EXPORT) L161 18LG/OR V10 18BR F1 16DB X3 20BK/RD F12 18DB/WT L50 20WT/TN...
Page 377 2001 NEON 8Wa - 80 - 12 8W-80 CONNECTOR PINOUTS C105 - BLACK (HD/LP & DASH SIDE) CIRCUIT A141 18DG/WT K106 18WT/DG (LHD) K107 18YL (LHD) L1 18VT/BK L7 18BK/YL M1 20PK C105 - BLACK 10 WAY (UNIBODY SIDE) CIRCUIT A141 18DG/WT K106 18WT/DG (EXCEPT BUILT-UP- EXPORT)
Page 378 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 13 C108 - BLACK (HD/LP & DASH SIDE) CIRCUIT F12 18DB/WT (2.0L) F20 20WT K54 18OR/BK (2.0L) L1 18VT/BK T41 18BR/YL (2.0L) C108 - BLACK (TRANS SIDE) CIRCUIT F12 18DB/WT (ATX) F20 20WT K54 18OR/BK (ATX) L1 18VT/BK...
Page 379 2001 NEON 8Wa - 80 - 14 8W-80 CONNECTOR PINOUTS C112 (1.6L) - BLACK (HD/LP & DASH SIDE) CIRCUIT K80 20DG/LG F858 20PK K167 20BR/YL K81 20DB/DG F859 20DG/PK K981 20BR/DG C112 (1.6L) - BLACK (ENGINE SIDE) CIRCUIT K80 20DG/LG F858 20PK K167 20BR/YL K81 20DB/DG...
Page 380 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 15 C201 - (RT FRONT DOOR SIDE) CIRCUIT C16 20LB/YL (POWER MIRRORS/WIN- DOWS) F21 14TN (POWER MIRRORS/WIN- DOWS) Z14 18BK/YL Z14 18BK/YL (POWER LOCKS) Q16 14BR/WT (POWER MIRRORS/WIN- DOWS) Q26 14VT/WT (POWER MIRRORS/WIN- DOWS) G75 18TN/BK ( BASE) P33 18OR/BK (POWER LOCKS)
Page 381 2001 NEON 8Wa - 80 - 16 8W-80 CONNECTOR PINOUTS C202 - LT. GREEN (PLENUM SIDE) CIRCUIT V4 16RD/YL V3 16BR/WT V5 16DG/YL V6 16DB Z1 16BK C6 14LB C7 14BK/TN C4 14TN C5 14LG C203 - LT. GRAY (ROOF WIRING SIDE) CIRCUIT C2 22DB/YL F20 20WT...
Page 382 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 17 C204 - RED (I/P SIDE) CIRCUIT M1 20PK M2 18YL Z3 18BK/OR F10 18YL/RD C205 - GRAY (I/P SIDE) CIRCUIT C16 20LB/YL (POWER MIRRORS/WIN- DOWS) F21 14TN (POWER MIRRORS/WIN- DOWS) Z14 20BK/YL Q16 14BR/WT (POWER MIRRORS/WIN- DOWS)
Page 383 2001 NEON 8Wa - 80 - 18 8W-80 CONNECTOR PINOUTS C205 - (LH FRONT DOOR SIDE) CIRCUIT C16 20LB/YL (POWER MIRRORS/WIN- DOWS) F21 14TN (POWER MIRRORS/WIN- DOWS) Z14 18BK/YL Z14 18BK/YL (POWER LOCKS) Q16 14BR/WT (POWER MIRRORS/WIN- DOWS) Q26 14VT/WT (POWER MIRRORS/WIN- DOWS) P33 18OR/BK (POWER LOCKS) G75 18TN/BK (LHD) (BASE)
Page 384 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 19 C206 - LT. GRAY (I/P SIDE) CIRCUIT F15 18DG/WT (SIDE AIRBAG) D25 18VT/YL (SIDE AIRBAG) Z6 18BK/PK (SIDE AIRBAG) Z8 16BK/VT A120 16RD/LG C208 - YELLOW (SIDE AIRBAG JUMPER SIDE) CIRCUIT R32 18YL/OR R34 18OR/YL...
Page 385 2001 NEON 8Wa - 80 - 20 8W-80 CONNECTOR PINOUTS C210 (BUILT-UP-EXPORT) - BLACK (SIDE AIR- BAG JUMPER SIDE) CIRCUIT A120 16WT Z8 16BK C210 (BUILT-UP-EXPORT) - BLACK (POWER SEAT SIDE) CIRCUIT A120 16RD/LG Z1 16BK C301 - RED (DOME LAMP SIDE) CIRCUIT M1 20PK M2 18YL...
Page 386 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 21 C302 - BLACK (UNIBODY SIDE) CIRCUIT L50 20WT/TN Z1 14BK G78 22TN/BK (CARGO LAMP) G71 20VT/YL (ELECTRIC RELEASE) Q2 14LG/BK (ELECTRIC RELEASE) C303 - BLUE (UNIBODY SIDE) CIRCUIT M9 20LB/OR P33 18OR/BK (POWER LOCKS) P36 18PK/VT (POWER LOCKS) Z1 18BK...
Page 387 2001 NEON 8Wa - 80 - 22 8W-80 CONNECTOR PINOUTS C304 - BLACK (REAR DOOR SIDE) CIRCUIT M9 18LB/OR P33 18OR/BK (POWER LOCKS) P36 18PK/VT (POWER LOCKS) Z1 20BK C305 - NATURAL (UNIBODY SIDE) CIRCUIT L38 16BR/WT (BUILT-UP-EXPORT) G71 20VT/YL (POWER LOCKS) G10 20LG/RD L7 20BK/YL L62 18BR/RD...
Page 388 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 23 C305 - BLACK (I/P SIDE) CIRCUIT M9 20LB/OR G71 20VT/YL (RKE) G10 20LG/RD L7 20BK/YL L62 20BR/RD L63 20DG/RD X51 20BR/YL X52 20DB/WT L50 20WT/TN X5 22WT/RD (RHD) G120 18WT/DB (RHD) L38 16BR/WT (BUILT-UP-EXPORT) M2 18YL X57 20BR/LB...
Page 389 2001 NEON 8Wa - 80 - 24 8W-80 CONNECTOR PINOUTS CAMSHAFT POSITION SENSOR - BLACK 3 WAY CIRCUIT FUNCTION F854 20GY/PK (1.6L) CAMSHAFT POSITION SENSOR 8V SUPPLY K7 20OR (2.0L) 8V SUPPLY K44 20TN/YL (1.6L) CAMSHAFT POSITION SENSOR SIGNAL K4 20BK/LB (2.0L) SENSOR GROUND K944 20BR/GY (1.6L) CAMSHAFT POSITION SENSOR GROUND...
Page 390 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 25 CLOCKSPRING - GREEN 7 WAY CIRCUIT FUNCTION R45 18DG/LB DRIVER AIRBAG LINE 2 R43 18BK/LB DRIVER AIRBAG LINE 1 X3 22BK/RD HORN RELAY CONTROL V37 20RD/LG (SPEED CONTROL) SPEED CONTROL SWITCH SIGNAL Z9 20BK (SPEED CONTROL) GROUND CLUTCH INTERLOCK/UPSTOP SWITCH (MTX) - BLACK 3 WAY...
Page 391 2001 NEON 8Wa - 80 - 26 8W-80 CONNECTOR PINOUTS CONTROLLER ANTILOCK BRAKE - BLACK 25 WAY CIRCUIT FUNCTION B27 18RD/YL TRACTION CONTROL SWITCH SENSE L50 18WT/TN BRAKE LAMP SWITCH OUTPUT B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL B7 18WT 12 VOLT SUPPLY B2 18YL 12 VOLT SUPPLY...
Page 392 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 27 DECKLID RELEASE SWITCH (POWER RELEASE) - BLACK 2 WAY CIRCUIT FUNCTION Q33 18BR/LB DECKLID RELEASE RELAY CONTROL Z1 18BK GROUND DECKLID SOLENOID - BLACK 2 WAY CIRCUIT FUNCTION Q2 14LG/BK DECKLID RELEASE RELAY OUTPUT Z1 14BK GROUND...
Page 393 2001 NEON 8Wa - 80 - 28 8W-80 CONNECTOR PINOUTS DOME LAMP/INTRUSION SENSOR (BUILT-UP-EXPORT) - NATURAL 4 WAY CIRCUIT FUNCTION M2 18YL COURTESY LAMP CONTROL M1 20PK FUSED B(+) Z1 18BK GROUND G120 18WT/DB INTRUSION SENSOR SIGNAL DRIVER AIRBAG - YELLOW 2 WAY CIRCUIT FUNCTION R43 18BK/LB...
Page 394 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 29 DRIVER DOOR LOCK MOTOR/AJAR SWITCH - BLACK 4 WAY CIRCUIT FUNCTION G74 18TN/BK (RHD) RIGHT FRONT DOOR AJAR SWITCH SENSE G75 18TN/BK (LHD) LEFT FRONT DOOR AJAR SWITCH SENSE Z14 18BK/YL GROUND P34 18PK/BK DRIVER DOOR UNLOCK UNLOCK RELAY OUTPUT...
Page 395 2001 NEON 8Wa - 80 - 30 8W-80 CONNECTOR PINOUTS DRIVER POWER WINDOW MOTOR - BLACK 2 WAY CIRCUIT FUNCTION Q21 14WT/LB DRIVER WINDOW DRIVER DOWN Q11 14LB DRIVER WINDOW DRIVER UP DRIVER POWER WINDOW SWITCH C1 - BLACK 8 WAY CIRCUIT FUNCTION Z8 14BK/VT...
Page 396 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 31 ENGINE COOLANT TEMPERATURE SENSOR (1.6L) - BLACK 2 WAY CIRCUIT FUNCTION K4 20BK/LB SENSOR GROUND K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL ENGINE COOLANT TEMPERATURE SENSOR (2.0L) - BLACK 2 WAY CIRCUIT FUNCTION K4 20BK/LB...
Page 397 2001 NEON 8Wa - 80 - 32 8W-80 CONNECTOR PINOUTS FUEL INJECTOR NO. 2 - BLACK 2 WAY CIRCUIT FUNCTION K12 18TN FUEL INJECTOR NO.2 DRIVER A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO. 3 - BLACK 2 WAY CIRCUIT FUNCTION K13 18YL/WT...
Page 398 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 33 HEADLAMP LEVELING SWITCH (BUILT-UP-EXPORT) - BLACK 4 WAY CIRCUIT FUNCTION L13 20BR/YL HEADLAMP ADJUST SIGNAL L43 18VT FUSED LEFT LOW BEAM OUTPUT Z1 20BK GROUND E2 22OR PANEL LAMPS DRIVER HIGH NOTE HORN (DUAL HORNS) - BLACK 2 WAY CIRCUIT FUNCTION...
Page 399 2001 NEON 8Wa - 80 - 34 8W-80 CONNECTOR PINOUTS IGNITION SWITCH - BLACK 10 WAY CIRCUIT FUNCTION A1 14RD FUSED B(+) A21 14DB IGNITION SWITCH OUTPUT (RUN-START) F30 16RD IGNITION SWITCH OUTPUT (RUN-ACC) F1 16DB FUSED B(+) G26 22LB KEY-IN IGNITION SWITCH SENSE A41 14YL IGNITION SWITCH OUTPUT (START)
Page 400 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 35 INSTRUMENT CLUSTER - BLACK 26 WAY CIRCUIT FUNCTION E2 22OR PANEL LAMPS DRIVER M9 20LB/OR (RHD) PASSENGER DOOR AJAR/RKE SENSE M9 20DB/OR (LHD) PASSENGER DOOR AJAR/RKE SENSE L7 20BK/YL HEADLAMP SWITCH OUTPUT G5 18TN (LHD-EXCEPT RKE) FUSED IGNITION SWITCH OUTPUT (RUN-START) G5 20DB/WT...
Page 401 2001 NEON 8Wa - 80 - 36 8W-80 CONNECTOR PINOUTS LEFT BACK-UP LAMP - BLACK 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L1 18VT/BK BACK-UP LAMP FEED LEFT FRONT DOOR SPEAKER - BLACK 2 WAY CIRCUIT FUNCTION X53 20DG LEFT FRONT SPEAKER (+) X55 20BR/RD LEFT FRONT SPEAKER (-) LEFT FRONT FOG LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY...
Page 402 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 37 LEFT FRONT TURN SIGNAL LAMP (BUILT-UP-EXPORT) - NATURAL 3 WAY CIRCUIT FUNCTION L161 18LG/OR LEFT TURN SIGNAL L250 18WT (EATX) DUMMY CIRCUIT PLUG Z1 18BK GROUND LEFT FRONT WHEEL SPEED SENSOR - BLACK 2 WAY CIRCUIT FUNCTION B9 18RD...
Page 403 2001 NEON 8Wa - 80 - 38 8W-80 CONNECTOR PINOUTS LEFT LAVALIER MODULE (BUILT-UP-EXPORT) - BLACK 4 WAY CIRCUIT FUNCTION L7 18BK/YL HEADLAMP SWITCH OUTPUT Z1 18BK GROUND L13 20BR/YL HEADLAMP ADJUST SIGNAL L44 18VT/RD FUSED RIGHT LOW BEAM OUTPUT LEFT LICENSE LAMP (BUILT-UP-EXPORT) - NATURAL 2 WAY CIRCUIT FUNCTION...
Page 404 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 39 LEFT REAR FOG LAMP (BUILT-UP-EXPORT) - GRAY 3 WAY CIRCUIT FUNCTION Z1 16BK GROUND L38 16BR/WT REAR FOG LAMP FEED LEFT REAR SPEAKER - BLACK 2 WAY CIRCUIT FUNCTION X57 18BR/LB LEFT REAR SPEAKER (-) X51 18BR/YL LEFT REAR SPEAKER (+)
Page 405 2001 NEON 8Wa - 80 - 40 8W-80 CONNECTOR PINOUTS LEFT SIDE IMPACT AIRBAG CONTROL MODULE - 8 WAY CIRCUIT FUNCTION F15 18DG/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) R33 18OR/YL LEFT SEAT SQUIB LINE 1 R31 18YL/OR LEFT SEAT SQUIB LINE 2 Z6 18BK/PK GROUND D25 18VT/YL...
Page 406 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 41 LICENSE LAMP (EXCEPT BUILT-UP-EXPORT) - NATURAL 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL HEADLAMP SWITCH OUTPUT LOW NOTE HORN - BLACK 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND X2 18DG/RD HORN RELAY OUTPUT MANIFOLD ABSOLUTE PRESSURE SENSOR - 3 WAY...
Page 407 2001 NEON 8Wa - 80 - 42 8W-80 CONNECTOR PINOUTS MULTI-FUNCTION SWITCH - GRAY 20 WAY CIRCUIT FUNCTION L50 20WT/TN BRAKE LAMP SWITCH OUTPUT L61 20LG LEFT TURN SIGNAL L61 20LG (BUILT-UP-EXPORT) LEFT TURN SIGNAL L6 20RD/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC) L63 20DG/RD LEFT TURN SIGNAL L631 20DG/RD (BUILT-UP-EXPORT)
Page 408 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 43 OXYGEN SENSOR 1/2 DOWNSTREAM - BLACK 4 WAY CIRCUIT FUNCTION K199 20BR/LG (1.6L) (LHD) K199 18BR/VT (1.6L) (RHD) OXYGEN SENSOR 1/2 HEATER CONTROL Z1 18BK (2.0L) GROUND A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT K127 20DB/OR (1.6L) (LHD) OXYGEN SENSOR GROUND K127 18BK/OR...
Page 409 2001 NEON 8Wa - 80 - 44 8W-80 CONNECTOR PINOUTS PASSENGER DOOR LOCK MOTOR/AJAR SWITCH - BLACK 4 WAY CIRCUIT FUNCTION M9 18TN/BK (LHD) RIGHT FRONT DOOR AJAR SWITCH SENSE M9 18TN/BK (RHD) LEFT FRONT DOOR AJAR SWITCH SENSE Z14 18BK/YL GROUND P36 18PK/BK DOOR UNLOCK RELAY OUTPUT...
Page 410 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 45 PASSENGER POWER WINDOW MOTOR - BLACK 2 WAY CIRCUIT FUNCTION Q22 14VT PASSENGER WINDOW DRIVER (DOWN) Q12 14BR PASSENGER WINDOW DRIVER (UP) PASSENGER POWER WINDOW SWITCH - GRAY 8 WAY CIRCUIT FUNCTION Q26 14VT/WT...
Page 411 2001 NEON 8Wa - 80 - 46 8W-80 CONNECTOR PINOUTS POWER SEAT MOTOR (BUILT-UP-EXPORT) - 2 WAY CIRCUIT FUNCTION P121 16LG/OR SEAT DOWN DRIVER P120 16LG/YL SEAT UP DRIVER POWER SEAT SWITCH (BUILT-UP-EXPORT) - 6 WAY CIRCUIT FUNCTION Z1 16BK GROUND P120 16LG/YL SEAT UP DRIVER...
Page 412 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 47 POWERTRAIN CONTROL MODULE C1 (2.0L) - BLACK 40 WAY CIRCUIT FUNCTION K119 20LG/BK CLUTCH SWITCH K42 20DB/LG KNOCK SENSOR SIGNAL K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL K127 18BK/OR OXYGEN SENSOR GROUND K41 20BK/DG OXYGEN SENSOR 1/1 SIGNAL K90 20TN...
Page 413 2001 NEON 8Wa - 80 - 48 8W-80 CONNECTOR PINOUTS POWERTRAIN CONTROL MODULE C2 (2.0L) - BLACK 40 WAY CIRCUIT FUNCTION K108 20DB EVAPORATIVE EMISSION SOLENOID SENSE G15 18GY/RD BRAKE FLUID LEVEL SWITCH SENSE K107 18YL (LHD) LEAK DETECTION PUMP SWITCH SENSE K31 18BR FUEL PUMP RELAY CONTROL D20 20LG...
Page 414 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 49 POWERTRAIN CONTROL MODULE (1.6L) - 90 WAY CIRCUIT FUNCTION K107 18YL LEAK DETECTION PUMP SWITCH SENSE K10 20WT STEERING PRESSURE SWITCH SENSE G9 20GY/BK RED BRAKE WARNING INDICATOR DRIVER D20 20LG SCI RECEIVE K944 20BR/GY CAMSHAFT POSITION SENSOR GROUND...
Page 415 2001 NEON 8Wa - 80 - 50 8W-80 CONNECTOR PINOUTS PVC HEATER (2.0L) - BLACK 2 WAY CIRCUIT FUNCTION A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT Z1 18BK GROUND RADIATOR FAN MOTOR - BLACK 2 WAY CIRCUIT FUNCTION C25 12LG RADIATOR FAN RELAY OUTPUT Z1 14BK GROUND...
Page 416 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 51 RADIO C4 - BLACK 8 WAY CIRCUIT FUNCTION 24VT/YL PCI BUS 24GY/WT AUDIO OUT RIGHT 24OR/TN PANEL LAMPS DIMMER SIGNAL 24BK/OR GROUND 24DG/WT AUDIO OUT LEFT 22GY/YL B(+) 24RD IGNITION SWITCH OUTPUT 22BK/TN GROUND REAR WINDOW DEFOGGER SWITCH - BLACK 5 WAY...
Page 417 2001 NEON 8Wa - 80 - 52 8W-80 CONNECTOR PINOUTS REMOTE KEYLESS ENTRY MODULE - BLACK 26 WAY CIRCUIT FUNCTION G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) G70 20BR/TN HOOD AJAR SWITCH SENSE G71 20VT/YL DECKLID SECURITY SWITCH SENSE G74 18TN (RHD) RIGHT FRONT DOOR AJAR SWITCH SENSE G75 18TN (LHD) LEFT FRONT DOOR AJAR SWITCH SENSE...
Page 418 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 53 RIGHT FRONT SIDE MARKER LAMP (EXCEPT BUILT-UP-EXPORT) - NATURAL 2 WAY CIRCUIT FUNCTION Z1 20BK (EXCEPT EATX) GROUND L160 18TN/RD (EATX) RIGHT TURN SIGNAL L7 20BK/YL HEADLAMP SWITCH OUTPUT RIGHT FRONT TURN SIGNAL LAMP (BUILT-UP-EXPORT) - NATURAL 2 WAY CIRCUIT FUNCTION L160 18TN/RD...
Page 419 2001 NEON 8Wa - 80 - 54 8W-80 CONNECTOR PINOUTS RIGHT INSTRUMENT PANEL SPEAKER - BLACK 2 WAY CIRCUIT FUNCTION X54 20VT RIGHT FRONT SPEAKER (+) X56 20DB/RD RIGHT FRONT SPEAKER (-) RIGHT LAVALIER MODULE (BUILT-UP-EXPORT) - BLACK 4 WAY CIRCUIT FUNCTION L7 18BK/YL...
Page 420 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 55 RIGHT REAR DOOR LOCK MOTOR/AJAR SWITCH - BLACK 4 WAY CIRCUIT FUNCTION M9 18LB/OR PASSENGER DOOR AJAR/RKE SENSE Z8 18BK GROUND P36 18PK/VT DOOR UNLOCK RELAY DRIVER P33 18OR/BK DOOR LOCK RELAY DRIVER RIGHT REAR FOG LAMP (BUILT-UP-EXPORT) - GRAY 3 WAY CIRCUIT FUNCTION...
Page 421 2001 NEON 8Wa - 80 - 56 8W-80 CONNECTOR PINOUTS RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY CIRCUIT FUNCTION B2 20YL 12 VOLT SUPPLY B1 20YL/DB RIGHT REAR WHEEL SPEED SENSOR SIGNAL RIGHT SEAT AIRBAG - 2 WAY CIRCUIT FUNCTION R32 18OR...
Page 422 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 57 RIGHT TAIL/STOP/TURN SIGNAL LAMP (EXCEPT BUILT-UP-EXPORT) -BLACK 3 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL HEADLAMP SWITCH OUTPUT L62 18BR/RD RIGHT TURN SIGNAL RKE ANTENNA (JAPAN) - BLACK 2 WAY CIRCUIT FUNCTION X161 18WT...
Page 423 2001 NEON 8Wa - 80 - 58 8W-80 CONNECTOR PINOUTS SPEED CONTROL SERVO - BLACK 4 WAY CIRCUIT FUNCTION V36 20TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL V35 20LG/RD SPEED CONTROL VENT SOLENOID CONTROL V30 20DB/RD SPEED CONTROL BRAKE LAMP SWITCH OUTPUT Z1 20BK (LHD) GROUND Z1 18BK (RHD)
Page 424 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 59 SUNROOF VENT SWITCH - 3 WAY CIRCUIT FUNCTION Z3 18BK/VT GROUND Q46 20OR SUNROOF VENT SWITCH THROTTLE POSITION SENSOR - BLACK 3 WAY CIRCUIT FUNCTION K4 20BK/LB SENSOR GROUND K22 20OR/DB THROTTLE POSITION SENSOR SIGNAL K6 18VT/WT 5V SUPPLY...
Page 425 2001 NEON 8Wa - 80 - 60 8W-80 CONNECTOR PINOUTS TRANSMISSION CONTROL MODULE (EATX) - BLACK 60 WAY CIRCUIT FUNCTION T1 18LG/GY TRS T1 SENSE T3 18VT TRS T3 SENSE K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL D21 18PK SCI TRANSMIT A41 14YL IGNITION SWITCH OUTPUT (START) T9 18OR/BK...
Page 426 2001 NEON 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 61 TRANSMISSION CONTROL MODULE (EATX) - BLACK 60 WAY CIRCUIT FUNCTION Z14 16BK (EATX BUILT-UP-EXPORT) GROUND Z14 16BK/WT GROUND T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL A24 16RD/WT FUSED B(+) Z13 16BK (EATX BUILT-UP-EXPORT) GROUND Z13 16BK/WT (BUILT-UP-EXPORT) GROUND...
Page 427 2001 NEON 8Wa - 80 - 62 8W-80 CONNECTOR PINOUTS VEHICLE SPEED SENSOR - BLACK 3 WAY CIRCUIT FUNCTION K7 20OR (2.0L) 8V SUPPLY F857 20OR/PK (1.6L) VEHICLE SPEED SENSOR 8V SUPPLY N907 20BR/OR (1.6L) VEHICLE SPEED SENSOR GROUND K4 18BK/LB (2.0L) SENSOR GROUND G7 20WT/OR VEHICLE SPEED SENSOR SIGNAL...
Page 428 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 1 8W-90 CONNECTOR/GROUND LOCATIONS TABLE OF CONTENTS page page CONNECTOR/GROUND LOCATIONS DESCRIPTION - RHD..... . 22 DESCRIPTION - LHD .
Page 429 2001 NEON 8Wa - 90 - 2 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. C202 LT GN Right Upper Instrument Panel 7, 8 C203 LT GY Right Upper Instrument Panel 7, 8 C204 Left Upper Instrument Panel 7, 9, 10 C205 Left Lower Instrument Panel...
Page 430 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 3 CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Electronic Throttle Control Module Right Front of Engine (1.6L) Engine Coolant Temperature Sensor Right Front of Engine Engine Oil Pressure Switch Right Rear of Engine Evap Purge Solenoid Left Rear of Engine Fuel Injector NO.1...
Page 431 2001 NEON 8Wa - 90 - 4 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Left Back-Up Lamp Left Rear Fascia Left Front Door Speaker At Drivers Door Left Front Fog Lamp Lower Left Facia Left Front Side Marker Lamp Left Front Side Fender Left Front Turn Signal Lamp Left Front Facia...
Page 432 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 5 CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Park Brake Switch On Parking Brake Lever 7, 11 Park/Neutral Position Switch (ATX) Left Side of Transmission Passenger Airbag Right Side of Instrument Panel Passenger Cylinder Lock Switch At Passenger Door Passenger Door Ajar Switch...
Page 433 2001 NEON 8Wa - 90 - 6 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Right Park/Turn Signal Lamp (Except Lower Right Fascia Built-Up-Export) Right Rear Door Ajar Switch Right Rear Lower Door Opening Right Rear Door Lock Motor/Ajar Right Rear Door Switch Right Rear Fog Lamp (Built-Up-...
Page 434 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 7 CONNECTOR/GROUND LOCATIONS (Continued)
Page 435 2001 NEON 8Wa - 90 - 8 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 436 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 9 CONNECTOR/GROUND LOCATIONS (Continued)
Page 437 2001 NEON 8Wa - 90 - 10 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 4 ENGINE CONNECTIONS (RIGHT FRONT) - LHD Fig. 5 ENGINE CONNECTIONS (LEFT REAR) - LHD...
Page 438 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 11 CONNECTOR/GROUND LOCATIONS (Continued)
Page 439 2001 NEON 8Wa - 90 - 12 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 440 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 13 CONNECTOR/GROUND LOCATIONS (Continued)
Page 441 2001 NEON 8Wa - 90 - 14 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 442 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 15 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 10 ROOF CONNECTIONS - LHD Fig. 11 CENTER CONSOLE CONNECTIONS - LHD...
Page 443 2001 NEON 8Wa - 90 - 16 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 444 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 17 CONNECTOR/GROUND LOCATIONS (Continued)
Page 445 2001 NEON 8Wa - 90 - 18 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 14 BODY CONNECTIONS (RIGHT REAR) - LHD...
Page 446 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 19 CONNECTOR/GROUND LOCATIONS (Continued)
Page 447 2001 NEON 8Wa - 90 - 20 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 16 DOOR CONNECTIONS (DRIVER) - LHD Fig. 17 DOOR CONNECTIONS (PASSENGER) - LHD...
Page 448 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 21 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 18 DOOR CONNECTIONS (REAR) - LHD Fig. 19 DECKLID CONNECTIONS - LHD...
Page 449 2001 NEON 8Wa - 90 - 22 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) DESCRIPTION - RHD diagrams in each section for connector and ground identification. Refer to the index for the proper figure This section provides illustrations identifying con- number. For items that are not shown in this section nector and ground locations in the vehicle.
Page 450 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 23 CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. C304 BL/BK Right B-Pillar at Rear Door 32, 34, 38 C305 Left Side of Instrument Panel 28, 29, 32 C306 Center of Headliner Camshaft Position Sensor Rear of Engine Cargo Lamp...
Page 451 2001 NEON 8Wa - 90 - 24 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. G106 (2.0L) Left Front of Engine Compartment G107 Right Front of Engine Compartment 22, 23 G108 Right Front of Engine Compartment G109 Right Front of Engine Compartment G201 Lower Center of Instrument Panel...
Page 452 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 25 CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Left Rear Turn Signal Lamp Left Rear Facia Left Rear Wheel Speed Sensor At Left Rear Wheel Opening Left Seat Airbag Left Side of Seat Left Side Impact Airbag Control Left Side of Passenger Compartment Module...
Page 453 2001 NEON 8Wa - 90 - 26 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Rear Window Defogger Right Side of Rear Window Rear Window Defogger Switch Lower Center of Instrument Panel Remote Keyless Entry Module Upper Center of Instrument Panel 27, 28 Right Back-Up Lamp Right Rear Luggage Compartment...
Page 454 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 27 CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Transmission Solenoid/ Pressure Lower Left Engine Compartment Switch Assembly (EATX) Underhood Lamp At Lamp Vehicle Speed Sensor Right Front Wheel Opening Windshield Washer Pump Left Rear Engine Compartment Wiper/Washer Switch Lower Center of Instrument Panel...
Page 455 2001 NEON 8Wa - 90 - 28 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 456 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 29 CONNECTOR/GROUND LOCATIONS (Continued)
Page 457 2001 NEON 8Wa - 90 - 30 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 458 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 31 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 23 ENGINE CONNECTIONS (RIGHT FRONT) - RHD Fig. 24 ENGINE CONNECTIONS (LEFT REAR) - RHD...
Page 459 2001 NEON 8Wa - 90 - 32 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 460 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 33 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 26 LEFT SIDE ENGINE COMPARTMENT - RHD...
Page 461 2001 NEON 8Wa - 90 - 34 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 462 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 35 CONNECTOR/GROUND LOCATIONS (Continued)
Page 463 2001 NEON 8Wa - 90 - 36 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 464 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 37 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 30 ROOF CONNECTIONS - RHD Fig. 31 CENTER CONSOLE - RHD...
Page 465 2001 NEON 8Wa - 90 - 38 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 466 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 39 CONNECTOR/GROUND LOCATIONS (Continued)
Page 467 2001 NEON 8Wa - 90 - 40 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 34 BODY CONNECTIONS - RHD...
Page 468 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 41 CONNECTOR/GROUND LOCATIONS (Continued)
Page 469 2001 NEON 8Wa - 90 - 42 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 36 DOOR CONNECTIONS (PASSENGER) - RHD Fig. 37 DOOR CONNECTIONS (DRIVER) - RHD...
Page 470 2001 NEON 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 43 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 38 DOOR CONNECTIONS (REAR) - RHD Fig. 39 DECKLID CONNECTIONS - RHD...
Page 471 2001 NEON...
Page 472 2001 NEON 8W-95 SPLICE LOCATIONS 8Wa - 95 - 1 8W-95 SPLICE LOCATIONS TABLE OF CONTENTS page page SPLICE LOCATIONS DESCRIPTION - RHD..... . 18 DESCRIPTION - LHD .
Page 473 2001 NEON 8Wa - 95 - 2 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued) Splice Location Fig. S133 Near Underhood Lamp T/O S134 Near Underhood Lamp T/O S135 Near Crankshaft Position Sensor T/O S136 Near Inline C101 T/O S137 Near Throttle Position Sensor T/O S138 Near Transmission Range Sensor T/O S139...
Page 474 2001 NEON 8W-95 SPLICE LOCATIONS 8Wa - 95 - 3 SPLICE LOCATIONS (Continued) Splice Location Fig. S227 Near Inline C103/C104/C105 S229 Near Airbag Control Module T/O S230 Near Transmission Range Indicator Illumination (PRNDL) S231 Near Sentry Key Immobilizer Module T/O S232 Near Sentry Key Immobilizer Module T/O S233...
Page 475 2001 NEON 8Wa - 95 - 4 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
Page 476 2001 NEON 8W-95 SPLICE LOCATIONS 8Wa - 95 - 5 SPLICE LOCATIONS (Continued)
Page 477 2001 NEON 8Wa - 95 - 6 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
Page 478 2001 NEON 8W-95 SPLICE LOCATIONS 8Wa - 95 - 7 SPLICE LOCATIONS (Continued)
Page 479 2001 NEON 8Wa - 95 - 8 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
Page 480 2001 NEON 8W-95 SPLICE LOCATIONS 8Wa - 95 - 9 SPLICE LOCATIONS (Continued)
Page 481 2001 NEON 8Wa - 95 - 10 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
Page 482 2001 NEON 8W-95 SPLICE LOCATIONS 8Wa - 95 - 11 SPLICE LOCATIONS (Continued) Fig. 8 INSTRUMENT PANEL SPLICES (TOP REAR) - LHD Fig. 9 ROOF SPLICES - LHD...
Page 483 2001 NEON 8Wa - 95 - 12 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued) Fig. 10 CENTER CONSOLE SPLICES - LHD...
Page 484 2001 NEON 8W-95 SPLICE LOCATIONS 8Wa - 95 - 13 SPLICE LOCATIONS (Continued)
Page 485 2001 NEON 8Wa - 95 - 14 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
Page 486 2001 NEON 8W-95 SPLICE LOCATIONS 8Wa - 95 - 15 SPLICE LOCATIONS (Continued)
Page 487 2001 NEON 8Wa - 95 - 16 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
Page 488 2001 NEON 8W-95 SPLICE LOCATIONS 8Wa - 95 - 17 SPLICE LOCATIONS (Continued) Fig. 15 DOOR SPLICES - LHD Fig. 16 DECKLID SPLICES - LHD...
Page 489 2001 NEON 8Wa - 95 - 18 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued) DESCRIPTION - RHD section for splice number identification. Refer to the index for proper splice number. For splices that are This section provides illustrations identifying the not shown in the figures N/S appears in the Fig. col- general location of the splices in this vehicle.
Page 490 2001 NEON 8W-95 SPLICE LOCATIONS 8Wa - 95 - 19 SPLICE LOCATIONS (Continued) Splice Location Fig. S143 Near Powertrain Control Module-C2 S144 Near Transmission Control Module S145 Near Transmission Control Module T/O S146 Near Powertrain Control Module-C2 T/O S147 Near Left Park/Turn Signal Lamp S148 Near A/C High Pressure Switch T/O S149...
Page 491 2001 NEON 8Wa - 95 - 20 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued) Splice Location Fig. S237 Near Left Side Impact Airbag Control Module T/O S238 Near Power Seat Switch T/O S240 Near Driver Power Mirror T/O S241 Near Power Mirror Switch T/O S242 Near Driver Power Mirror T/O S251...
Page 492 2001 NEON 8W-95 SPLICE LOCATIONS 8Wa - 95 - 21 SPLICE LOCATIONS (Continued)
Page 493 2001 NEON 8Wa - 95 - 22 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
Page 494 2001 NEON 8W-95 SPLICE LOCATIONS 8Wa - 95 - 23 SPLICE LOCATIONS (Continued)
Page 495 2001 NEON 8Wa - 95 - 24 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
Page 496 2001 NEON 8W-95 SPLICE LOCATIONS 8Wa - 95 - 25 SPLICE LOCATIONS (Continued)
Page 497 2001 NEON 8Wa - 95 - 26 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
Page 498 2001 NEON 8W-95 SPLICE LOCATIONS 8Wa - 95 - 27 SPLICE LOCATIONS (Continued)
Page 499 2001 NEON 8Wa - 95 - 28 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued) Fig. 24 ROOF SPLICES - RHD Fig. 25 CENTER CONSOLE SPLICES - RHD...
Page 500 2001 NEON 8W-95 SPLICE LOCATIONS 8Wa - 95 - 29 SPLICE LOCATIONS (Continued)
Page 501 2001 NEON 8Wa - 95 - 30 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
Page 502 2001 NEON 8W-95 SPLICE LOCATIONS 8Wa - 95 - 31 SPLICE LOCATIONS (Continued) Fig. 28 DOOR SPLICES - RHD Fig. 29 DECKLID SPLICES - RHD...
Page 503 2001 NEON...
Page 504 2001 NEON ENGINE-2.0L SOHC 9s - 1 ENGINE-2.0L SOHC TABLE OF CONTENTS page page ENGINE-2.0L SOHC REMOVAL ....... 4 DESCRIPTION .
Page 505 2001 NEON 9s - 2 ENGINE-2.0L SOHC OIL PRESSURE SENSOR/SWITCH (Continued) (4) Remove fuel rail cover by pulling up to disen- gage from retaining pins (Fig. 3). Fig. 2 Engine Oil Pressure Switch INTAKE MANIFOLD-HIGH Fig. 3 INJECTOR COVER ASSEMBLY OUTPUT (5) Disconnect fuel injector connector and harness from injectors and fuel rail.
Page 506 2001 NEON ENGINE-2.0L SOHC 9s - 3 INTAKE MANIFOLD-HIGH OUTPUT (Continued) (9) Remove engine oil dipstick from housing. (10) Disconnect electrical connectors from MAP sensor and MTV actuator (Fig. 5). Fig. 6 Knock Sensor 1 - KNOCK SENSOR 2 - STARTER MOTOR Fig.
Page 507 2001 NEON 9s - 4 ENGINE-2.0L SOHC INTAKE MANIFOLD-HIGH OUTPUT (Continued) EXHAUST MANIFOLD-HIGH OUTPUT DESCRIPTION The exhaust manifold (Fig. 10) is a welded con- struction using lightweight tubular steel with stamped plate steel mounting flanges. The manifold attaches to the cylinder head. Fig.
Page 508 2001 NEON ENGINE-2.0L SOHC 9s - 5 EXHAUST MANIFOLD-HIGH OUTPUT (Continued) (11) Remove upper heat shield for access to mani- fold bolts. (12) Remove exhaust manifold bolts. (13) Remove exhaust manifold from top of vehicle, between the cylinder head and cowl. INSTALLATION (1) Position exhaust manifold and gasket in place.
Page 509 2001 NEON 9s - 6 ENGINE-2.0L SOHC VALVE TIMING (5) Remove right engine mount to engine mount bracket bolt. (6) Remove power steering pump assembly and set STANDARD PROCEDURE - VALVE TIMING aside. VERIFICATION (7) Remove right engine mount bracket. (Refer to 9 (1) Remove number one spark plug.
Page 510 2001 NEON ENGINE-2.0L SOHC 9s - 7 TIMING BELT COVER(S) (Continued) Fig. 16 Modification to Special Tool C-4687-1 1 - GRIND LOCATION 2 - 12.7 MM (1/2 IN.) 3 - 50.8 MM (2 IN.) INSTALLATION Fig. 17 Timing Belt Rear Cover 1 - BOLTS REAR COVER (1) Install rear cover and tighten bolts to 12 N·m...
Page 511 2001 NEON 9s - 8 ENGINE-2.0L SOHC TIMING BELT AND (7) Remove the engine right mount to engine mount bracket through bolt. SPROCKETS (8) Remove the power steering pump assembly and set aside. REMOVAL (9) Remove the engine mount bracket (Fig. 19). (1) Remove the accessory drive belts.
Page 512 2001 NEON ENGINE-2.0L SOHC 9s - 9 TIMING BELT AND SPROCKETS (Continued) (13) Remove the timing belt from sprockets. CAUTION: Do not rotate the camshaft once the tim- ing belt has been removed or damage to valve com- ponents may occur. Fig.
Page 513 2001 NEON 9s - 10 ENGINE-2.0L SOHC TIMING BELT AND SPROCKETS (Continued) Fig. 22 TENSIONER PULLEY ASSEMBLY Fig. 25 Adjusting Crankshaft Sprocket for Timing 1 - BRACKET Belt 2 - PULLEY BOLT 3 - PULLEY 1 - TDC REFERENCE MARK 4 - PULLEY PIVOT BRACKET 2 - 1/2 NOTCH LOCATION 5 - PIVOT BOLT (DO NOT REMOVE)
Page 514 2001 NEON ENGINE-2.0L SOHC 9s - 11 TIMING BELT AND SPROCKETS (Continued) (11) Pull the tensioner plunger retaining pin. Pre- (22) Install accessory drive belts. (Refer to 7 - tension is correct when the pin can be removed and COOLING/ACCESSORY DRIVE/DRIVE BELTS - installed into tensioner housing and plunger.
Page 515 2001 NEON...
Page 516 2001 NEON 21S-TRANSAXLE 21s - 1 21S-TRANSAXLE TABLE OF CONTENTS page page 21S-TRANSAXLE 31TH AUTOMATIC TRANSAXLE ... . . 22 DESCRIPTION ......1 41TE AUTOMATIC TRANSAXLE .
Page 517 2001 NEON 21s - 2 A578 MANUAL TRANSMISSION A578 MANUAL TRANSMISSION (Continued) SLIPS OUT OF GEAR Transaxle disengagement may be caused by mis- aligned or damaged shift components, or worn teeth on the drive gears or synchronizer components. Incor- rect assembly also causes gear disengagement. LOW LUBRICANT LEVEL Insufficient transaxle lubricant is usually the result of leaks, or inaccurate fluid level check or refill...
Page 518 2001 NEON A578 MANUAL TRANSMISSION 21s - 3 A578 MANUAL TRANSMISSION (Continued) (10) Disconnect the vehicle speed sensor connector (Fig. 5). Fig. 3 Clutch Slave Cylinder Connection 1 - SLAVE CYLINDER 2 - HYDRAULIC TUBE (8) Remove shift cable-to-bracket clips (Fig. 4). (9) Disconnect shift selector and crossover cable from levers (Fig.
Page 519 2001 NEON 21s - 4 A578 MANUAL TRANSMISSION A578 MANUAL TRANSMISSION (Continued) Fig. 8 Starter Motor Removal/Installation—Typical 1 - BOLT 2 - GROUND 3 - STARTER Fig. 6 Left Lateral Bending Brace and Structural 4 - BOLT Collar—Typical 1 - LATERAL BENDING BRACE 2 - STRUCTURAL COLLAR 3 - DUST COVER Fig.
Page 520 2001 NEON A578 MANUAL TRANSMISSION 21s - 5 A578 MANUAL TRANSMISSION (Continued) Fig. 10 Transaxle Removal/Installation 1 - MODULAR CLUTCH ASSEMBLY 3 - TRANSAXLE 2 - CLIP 4 - CLUTCH MODULE BOLT (4) (25) If installing a new or replacement transaxle, remove the upper mount as shown in (Fig.
Page 521 2001 NEON 21s - 6 A578 MANUAL TRANSMISSION A578 MANUAL TRANSMISSION (Continued) (c) Tighten the collar-to-transaxle bolts to 108 (a) Connect the accelerator and speed control (if N·m (80 ft. lbs.) torque. equipped) cables to the air cleaner/throttle body (d) Final torque the collar-to-oil pan bolts to 54 assy.
Page 522 2001 NEON A578 MANUAL TRANSMISSION 21s - 7 A578 MANUAL TRANSMISSION (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. Output Bearing Race Ret. — Strap Reverse Fork Bracket — Reverse Idler Shaft Bolt — Shift Cable Bracket to — Transaxle Transaxle Case Bolts —...
Page 523 2001 NEON 21s - 8 A578 MANUAL TRANSMISSION A578 MANUAL TRANSMISSION (Continued) Adapter C-4996 Universal Handle C-4171 Installer L-4410 Bearing Installer C-4628 Seal Remover C-4680 Special Jaw Set L-4518 Seal Installer C-4992 Bearing Splitter 1130 Torque Tool Driver 6342...
Page 524 2001 NEON A578 MANUAL TRANSMISSION 21s - 9 A578 MANUAL TRANSMISSION (Continued) Remover 6787 DIFFERENTIAL Disconnect Tool 6638A DISASSEMBLY (1) Remove differential bearing cones (ring gear and diff. case side) using Tool C-293-PA, Adapters C-293-45, and Tool 4996 (Fig. 12) (Fig. 13). Seal Installer 6709 Bearing Remover 6768 Fig.
Page 525 2001 NEON 21s - 10 A578 MANUAL TRANSMISSION DIFFERENTIAL (Continued) (3) Using a suitable screwdriver, pry off speedom- eter drive gear (Fig. 15) (Fig. 16). Fig. 13 Remove Differential Bearing Cone from Ring Gear Side 1 - SPECIAL TOOL C-293 Fig.
Page 526 2001 NEON A578 MANUAL TRANSMISSION 21s - 11 DIFFERENTIAL (Continued) (4) Using hammer and suitable punch, remove pin- (5) Remove pinion shaft (Fig. 19). ion shaft retaining pin (Fig. 17) (Fig. 18). Fig. 19 Pinion Shaft Removal Fig. 17 Remove Pinion Shaft Retaining Pin 1 - DIFFERENTIAL ASSEMBLY 2 - PINION SHAFT 1 - RING GEAR...
Page 527 2001 NEON 21s - 12 A578 MANUAL TRANSMISSION DIFFERENTIAL (Continued) Fig. 21 Differential Components 1 - DIFFERENTIAL ASSEMBLY 5 - PINION GEAR THRUST WASHERS 2 - PINION SHAFT 6 - PINION GEARS 3 - SPEEDOMETER DRIVE GEAR 7 - SIDE GEARS 4 - SIDE GEAR THRUST WASHERS (SELECT THICKNESS) 8 - PINION SHAFT RETAINING PIN (4) Stake case to retain pin as shown in (Fig.
Page 528 2001 NEON A578 MANUAL TRANSMISSION 21s - 13 DIFFERENTIAL (Continued) Fig. 26 Speedometer Drive Gear 1 - SPEEDOMETER DRIVE GEAR 2 - DIFFERENTIAL ASSEMBLY (7) Using an arbor press, steel block, and Tool L-4440, press speedometer drive gear onto differen- Fig.
Page 529 2001 NEON 21s - 14 A578 MANUAL TRANSMISSION DIFFERENTIAL (Continued) Fig. 28 Drive Gear Pressed onto Differential Fig. 30 Checking Side Gear End Play (Typical) 1 - PRESS RAM 1 - SPECIAL TOOL C-4996 (NOTE POSITION) 2 - SPEEDOMETER DRIVE GEAR 2 - DIAL INDICATOR SET 3 - DIFFERENTIAL ASSEMBLY 3 - DIFFERENTIAL ASSEMBLY...
Page 530 2001 NEON A578 MANUAL TRANSMISSION 21s - 15 DIFFERENTIAL (Continued) DIFFERENTIAL BEARING PRELOAD ADJUSTMENT / SHIM SELECTION Measure and adjust differential side bearing pre- load during any transaxle service, especially when the following components are replaced: • Transaxle gear case •...
Page 531 2001 NEON 21s - 16 A578 MANUAL TRANSMISSION SHIFT MECHANISM (4) Remove crossover cable retaining clip and dis- connect from shift lever (Fig. 36). REMOVAL (1) Lift up on gearshift boot to disengage retainer tabs from console. (2) Push down on knob and rotate clockwise to remove knob/boot assembly (Fig.
Page 532 2001 NEON A578 MANUAL TRANSMISSION 21s - 17 SHIFT MECHANISM (Continued) Fig. 39 Gearshift Knob/Boot Removal 1 - GEARSHIFT KNOB Fig. 38 Shifter Assy. Removal/Installation 1 - SHIFTER ASSEMBLY INSTALLATION (1) Install shifter assy. to floor pan (Fig. 38). Install and tighten four nuts to 12 N·m (105 in. lbs.) torque.
Page 533 2001 NEON 21s - 18 A578 MANUAL TRANSMISSION GEAR SHIFT CABLE (Continued) Fig. 41 Crossover Cable at Shifter Assembly 1 - GROMMET PLATE NUT 2 - SHIFTER Fig. 43 Air Cleaner Assembly Removal/Installation 3 - CROSSOVER CABLE 4 - CLIP 1 - AIR CLEANER ASSY.
Page 534 2001 NEON A578 MANUAL TRANSMISSION 21s - 19 GEAR SHIFT CABLE (Continued) INSTALLATION (10) Raise vehicle on hoist. (11) Remove converter heat shield (Fig. 45). NOTE: The crossover and selector cables are man- ufactured as a cable “assembly” and cannot be ser- viced individually.
Page 535 2001 NEON 21s - 20 A578 MANUAL TRANSMISSION GEAR SHIFT CABLE (Continued) ADJUSTMENTS (c) Perform functional check by shifting trans- axle into all gears. NOTE: Only the crossover cable is adjustable. The selector cable does not have adjustment capabili- ties. (1) Disengage gearshift boot retaining tabs to free it from console.
Page 536 2001 NEON A578 MANUAL TRANSMISSION 21s - 21 GEAR SHIFT CABLE (Continued) (4) Loosen crossover adjustment screw at shifter (5) The gearshift mechanism and transaxle cross- assembly (Fig. 50). over lever are spring-loaded and self-centering. Align- ment pins used in the past are not required anymore. Allow gearshift mechanism and transaxle crossover lever to relax in their neutral positions.
Page 537 2001 NEON 21s - 22 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE TABLE OF CONTENTS page page 31TH AUTOMATIC TRANSAXLE OPERATION......60 DIAGNOSIS AND TESTING .
Page 538 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 23 31TH AUTOMATIC TRANSAXLE (Continued) CLUTCHES BANDS LEVER START PARK (KICKDOWN) LOW/REV OVER- FRONT REAR LOCKUP RUNNING POSITION SAFETY SPRAG FRONT REAR P - PARK REVERSE NEUTRAL D - DRIVE First Second Third SECOND First Second...
Page 539 2001 NEON 21s - 24 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE (Continued) (3) Remove oil pan (Fig. 3). Clean sealing surfaces of old adhesive prior to reassembly. Fig. 3 Transaxle Oil Pan 1 - TRANSAXLE OIL PAN Fig. 1 Measure Input Shaft End Play using End Play 2 - OIL FILTER Set 8266 1 - TOOL 8266–8...
Page 540 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 25 31TH AUTOMATIC TRANSAXLE (Continued) (5) Remove oil filter and gasket (Fig. 5). (8) Remove park rod from transaxle (Fig. 7). Fig. 5 Oil Filter and Gasket Fig. 7 Parking Rod 1 - OIL FILTER 1 - VALVE BODY 2 - GASKET 2 - PARKING ROD...
Page 541 2001 NEON 21s - 26 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE (Continued) (10) Remove valve body-to-transaxle bolts (Fig. 9). (12) Loosen low/reverse band lock nut and adjust- ing screw to facilitate strut removal (Fig. 11). Fig. 9 Valve Body Attaching Bolts Fig.
Page 542 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 27 31TH AUTOMATIC TRANSAXLE (Continued) (14) Remove low/reverse servo retainer, spring, (16) Remove accumulator plate (Fig. 15). and servo (Fig. 13). Fig. 15 Accumulator Plate and Snap Ring Fig. 13 Remove Retainer, Spring and Servo 1 - SNAP RING 1 - SERVO PISTON 2 - ACCUMULATOR PLATE...
Page 543 2001 NEON 21s - 28 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE (Continued) (18) Loosen kickdown band adjusting screw lock (20) Remove kickdown servo snap ring (Fig. 19). nut (Fig. 17). Fig. 19 Kickdown Servo Snap Ring Fig. 17 Kickdown Band Adjusting Screw Lock Nut 1 - SNAP RING 2 - SNAP RING PLIERS 1 - KICKDOWN BAND ADJUSTING SCREW...
Page 544 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 29 31TH AUTOMATIC TRANSAXLE (Continued) (22) Remove kickdown servo spring and piston (23) Remove park sprag rod support-to-case bolts (Fig. 21). Disassemble kickdown servo assembly as (Fig. 23). shown in (Fig. 22). Fig. 23 Parking Sprag Rod Support 1 - PARKING SPRAG ROD SUPPORT Fig.
Page 545 2001 NEON 21s - 30 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE (Continued) NOTE: To remove pawl, spring, and pivot shaft, the (27) Install Tool C-3752 and adapters L-4437 as governor support retainer must be removed. (Refer shown in (Fig. 27). to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - 31TH/TRANSFER SYSTEM - REMOVAL) (25) Remove park pawl, spring, and pivot shaft...
Page 546 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 31 31TH AUTOMATIC TRANSAXLE (Continued) (29) Remove oil pump gasket (Fig. 29). (31) Remove front clutch assembly (Fig. 31). Fig. 29 Oil Pump Gasket Fig. 31 Front Clutch Assembly 1 - SPLIT IN GASKET (DIFFERENTIAL OIL FEED) 1 - REAR CLUTCH ASSEMBLY 2 - PUMP GASKET 2 - FRONT CLUTCH ASSEMBLY...
Page 547 2001 NEON 21s - 32 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE (Continued) (33) Remove #3 thrust washer (Fig. 33). (35) Remove front planetary gear assembly from output shaft (Fig. 35). (36) Remove #6 thrust washer from sun gear driv- ing shell (Fig. 35). Fig.
Page 548 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 33 31TH AUTOMATIC TRANSAXLE (Continued) (39) Remove rear planetary gear assembly (Fig. 39). Fig. 37 Sun Gear Driving Shell Components 1 - #8 THRUST WASHER (STEEL) 2 - #7 SPACER (STEEL) 3 - SUN GEAR Fig.
Page 549 2001 NEON 21s - 34 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE (Continued) (41) Remove overrunning clutch cam assembly (42) Remove low/reverse band (Fig. 43). (Fig. 41). Collect eight rollers and eight springs from rear of case (Fig. 42). Fig. 43 Low/Reverse Band and Strut 1 - #11 THRUST WASHER Fig.
Page 550 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 35 31TH AUTOMATIC TRANSAXLE (Continued) ASSEMBLY (2) Install low/reverse band (Fig. 46). Do not install strut or adjust at this time. CAUTION: If transaxle failure has occurred, it is necessary to flush the transaxle oil cooler and lines to remove debris and particles that could contami- nate and/or fail a new or rebuilt unit.
Page 551 2001 NEON 21s - 36 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE (Continued) (4) Orient springs as shown on left side of (Fig. (8) Install #9 thrust washer (Fig. 50). Use petrola- 48). tum to secure. Fig. 50 No. 9 Thrust Washer 1 - #9 THRUST WASHER 2 - OUTPUT SHAFT 3 - REAR PLANETARY GEAR ASSEMBLY...
Page 552 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 37 31TH AUTOMATIC TRANSAXLE (Continued) (10) Install front planetary gear assembly (Fig. (12) Install #3 thrust washer (Fig. 54). Refer to 52). end play specification recorded during transaxle dis- assembly to determine whether or not replacement is necessary.
Page 553 2001 NEON 21s - 38 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE (Continued) (14) Install #2 thrust washer (Fig. 55). (17) Install oil pump gasket (Fig. 58). (15) Install front clutch assembly (Fig. 56). Ensure that all clutch discs are engaged to rear clutch retainer splines or transaxle failure will result.
Page 554 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 39 31TH AUTOMATIC TRANSAXLE (Continued) (20) Set up tools as shown in (Fig. 60) to measure (22) Install rod support and bolts (Fig. 62). Torque input shaft end play. Input shaft end play should bolts to 28 N·m (250 in.
Page 555 2001 NEON 21s - 40 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE (Continued) (23) Assemble kickdown servo as shown in (Fig. (25) Install kickdown servo rod guide (Fig. 66). 64). Place snap ring into position for installation. Fig. 64 Controlled Load Kickdown Servo Fig.
Page 556 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 41 31TH AUTOMATIC TRANSAXLE (Continued) (27) Install kickdown band strut. (30) Install accumulator plate (Fig. 70) and place (28) Torque kickdown band adjusting screw (Fig. snap ring into position for installation. 68) to 8 N·m (72 in. lbs.) torque. Back off adjusting screw 2¼...
Page 557 2001 NEON 21s - 42 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE (Continued) (32) Install low/reverse servo piston, spring, and (34) Install low/reverse band strut. retainer (Fig. 72). (35) Adjust low/reverse band. Tighten adjusting nut (Fig. 74) to 5 N·m (41 in. lbs.) torque. Back off adjusting nut 3½...
Page 558 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 43 31TH AUTOMATIC TRANSAXLE (Continued) (37) Install and torque valve body-to-transaxle (39) Install park rod into position and retain with case bolts (Fig. 76) to 12 N·m (105 in. lbs.) torque. e-clip (Fig. 78). Fig.
Page 559 2001 NEON 21s - 44 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE (Continued) (41) Install oil filter-to-valve body screws (Fig. 80) and torque to 5 N·m (45 in. lbs.) torque. Fig. 82 Transaxle Oil Pan Bolts 1 - TRANSAXLE OIL PAN Fig.
Page 560 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 45 31TH AUTOMATIC TRANSAXLE (Continued) SCHEMATICS AND DIAGRAMS 31TH TRANSAXLE HYDRAULIC SCHEMATICS...
Page 561 2001 NEON 21s - 46 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE (Continued)
Page 562 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 47 31TH AUTOMATIC TRANSAXLE (Continued)
Page 563 2001 NEON 21s - 48 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE (Continued)
Page 564 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 49 31TH AUTOMATIC TRANSAXLE (Continued)
Page 565 2001 NEON 21s - 50 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE (Continued)
Page 566 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 51 31TH AUTOMATIC TRANSAXLE (Continued)
Page 567 2001 NEON 21s - 52 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE (Continued)
Page 568 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 53 31TH AUTOMATIC TRANSAXLE (Continued) SPECIFICATIONS 31TH AUTOMATIC TRANSAXLE GENERAL SPECIFICATIONS Three speed automatic with torque converter and Transaxle Type integral differential Cooling Method Water to oil heat exchanger Lubrication Method Pump (internal-external gear-type) GEAR RATIOS 1st Gear 2.69...
Page 569 2001 NEON 21s - 54 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE (Continued) OIL PUMP CLEARANCE Description Metric Standard Outer Gear-to-Pocket 0.045-0.141mm 0.0018-0.0056 in. Outer Gear Side Clearance 0.020-0.046mm 0.0008-0.0018 in. Inner Gear Side Clearance 0.020-0.046mm 0.0008-0.0018 in. THRUST WASHERS Description Metric Standard Reaction Shaft Support (No.
Page 570 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 55 31TH AUTOMATIC TRANSAXLE (Continued) Description N·m Ft. Lbs. In. Lbs. Bolt, Starter Motor-to- — Transaxle Bolt, Transaxle Case-to- — Engine Block Bolt, Transfer Gear — Cover-to-Case Bolt, Transfer Gear Strap — Bolt, Valve Body-to-Case —...
Page 571 2001 NEON 21s - 56 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE (Continued) SPECIAL TOOLS 31TH AUTOMATIC TRANSAXLE Spring Compressor C-3575-A Adapter Blocks C-293–45 Band Adjusting Adapter C-3705 Adapter Blocks C-293–52 Oil Pump Puller C-3752 Puller Press C-293–PA Throttle Setting Gauge C-3763 Pressure Gauge (High) C-3293SP Seal Puller C-3981B Dial Indicator C-3339...
Page 572 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 57 31TH AUTOMATIC TRANSAXLE (Continued) Torque Tool C-4995 Universal Handle C-4171 Adapter C-4996 Seal Installer C-4193A Remover Kit L-4406 Bearing Installer C-4637 Bearing Remover Cup L-4406–1 Adapter C-4658 Bearing Remover Jaws L-4406–2...
Page 573 2001 NEON 21s - 58 31TH AUTOMATIC TRANSAXLE 31TH AUTOMATIC TRANSAXLE (Continued) Adapter L-4406–3 Bearing Installer L-4411 Installer Adapter L-4429-3 Gear Puller L-4407A Gear Checking Plate L-4432 Puller L-4407–6 Gear Removing Plate L-4434 Bearing Installer L-4408 Bearing Puller L-4435 Bearing Installer L-4410...
Page 574 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 59 31TH AUTOMATIC TRANSAXLE (Continued) Differential Tool L-4436A Special Jaw Set L-4518 Housing Remover Adapter L-4437 Installer L-4520 Starter Nut L-4439 End Play Socket Set 8266 Transfer Shaft Remover-Installer L-4512 Bearing Splitter P-334 Bearing Cup Remover L-4517...
Page 575 2001 NEON 21s - 60 31TH AUTOMATIC TRANSAXLE BANDS KICKDOWN (FRONT) BAND DESCRIPTION The kickdown, or “front”, band (Fig. 83) holds the common sun gear of the planetary gear sets. The front (kickdown) band is made of steel, and faced on its inner circumference with a friction-type lining.
Page 576 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 61 ACCUMULATOR (Continued) accumulator, the combination of spring pressure and line pressure forces the piston away from the accu- mulator plate. This causes a balanced pressure situ- ation, which results in a cushioned band application. After the kickdown servo has become immovable, line pressure will finish pushing the accumulator up into its bore.
Page 577 2001 NEON 21s - 62 31TH AUTOMATIC TRANSAXLE FINAL DRIVE (Continued) DIFFERENTIAL BEARING SHIM CHART SHIM THICKNESS INCH .980 0.0386 1.02 0.0402 1.06 0.0418 1.10 0.0434 1.14 0.0449 1.18 0.0465 1.22 0.0481 1.26 0.0497 1.30 0.0512 Fig. 89 Checking Differential Bearings Turning 1.34 0.0528 Torque...
Page 578 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 63 GOVERNOR (Continued) weight assembly will start to move outward due to TORQUE CONVERTER centrifugal force. As the weight is moved outward, it will pull the valve with it until the land of the valve DESCRIPTION uncovers the line pressure port.
Page 579 2001 NEON 21s - 64 31TH AUTOMATIC TRANSAXLE TORQUE CONVERTER (Continued) IMPELLER The impeller (Fig. 91) is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the con- verter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving member of the system.
Page 580 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 65 TORQUE CONVERTER (Continued) TURBINE The turbine (Fig. 92) is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine.
Page 581 2001 NEON 21s - 66 31TH AUTOMATIC TRANSAXLE TORQUE CONVERTER (Continued) STATOR The stator assembly (Fig. 93) is mounted on a sta- tionary shaft which is an integral part of the oil pump. The stator is located between the impeller and turbine within the torque converter case (Fig.
Page 582 2001 NEON 31TH AUTOMATIC TRANSAXLE 21s - 67 TORQUE CONVERTER (Continued) Fig. 96 Torque Converter Fluid Operation 1 - APPLY PRESSURE 3 - RELEASE PRESSURE 2 - THE PISTON MOVES SLIGHTLY FORWARD 4 - THE PISTON MOVES SLIGHTLY REARWARD that was hitting the stator in such as way as to TURBINE cause it to lock–up is no longer doing so.
Page 583 2001 NEON 21s - 68 31TH AUTOMATIC TRANSAXLE TORQUE CONVERTER (Continued) TORQUE CONVERTER CLUTCH (TCC) (1) Lubricate converter hub and oil pump seal lip with transmission fluid. In a standard torque converter, the impeller and (2) Place torque converter in position on transmis- turbine are rotating at about the same speed and the sion.
Page 584 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 69 41TE AUTOMATIC TRANSAXLE TABLE OF CONTENTS page page 41TE AUTOMATIC TRANSAXLE PLANETARY GEARTRAIN DESCRIPTION ......70 DESCRIPTION .
Page 585 2001 NEON 21s - 70 41TE AUTOMATIC TRANSAXLE OPERATION......192 ASSEMBLY ......199 REMOVAL .
Page 586 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 71 41TE AUTOMATIC TRANSAXLE (Continued) 1 - CASE 7 - LOW/REVERSE CLUTCH 13 - DIFFERENTIAL 2 - INPUT SPEED SENSOR 8 - OUTPUT SPEED SENSOR 14 - OIL PUMP 3 - UNDERDRIVE CLUTCH 9 - PLANETARY GEAR SET 15 - TORQUE CONVERTER 4 - OVERDRIVE CLUTCH...
Page 587 2001 NEON 21s - 72 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) DIAGNOSIS AND TESTING - 41TE TRANSAXLE DIAGNOSIS AND TESTING - ROAD TEST GENERAL DIAGNOSIS Prior to performing a road test, verify that the fluid level, fluid condition, and linkage adjustment have been approved.
Page 588 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 73 41TE AUTOMATIC TRANSAXLE (Continued) The process of elimination can be used to detect any (5) This test checks pump output, pressure regula- unit which slips and to confirm proper operation of tion and condition of the low/reverse clutch hydraulic good units.
Page 589 2001 NEON 21s - 74 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) TEST FIVE-SELECTOR IN OVERDRIVE (4th Gear-CC (4) Reverse and LR clutch pressure should read 165 to 235 psi. (5) This test checks the reverse clutch hydraulic (1) Attach gauge to the torque converter clutch off circuit.
Page 590 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 75 41TE AUTOMATIC TRANSAXLE (Continued) DIAGNOSIS AND TESTING - CLUTCH AIR OVERDRIVE CLUTCH Apply air pressure to the overdrive clutch apply PRESSURE TESTS passage and watch for the push/pull piston to move Inoperative clutches can be located using a series forward.
Page 591 2001 NEON 21s - 76 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) Fig. 7 Converter Leak Points - Typical 1 - OUTSIDE DIAMETER WELD 2 - TORQUE CONVERTER HUB WELD 3 - STARTER RING GEAR 4 - LUG Fig. 6 Converter Housing Leak Paths 1 - PUMP SEAL (6) Disconnect input speed sensor connector.
Page 592 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 77 41TE AUTOMATIC TRANSAXLE (Continued) DISASSEMBLY (4) Remove oil pan-to-case bolts (Fig. 9). CAUTION: If transaxle failure has occurred, it is necessary to flush the transaxle oil cooler and lines to remove debris and particles that could contami- nate and/or fail a new or rebuilt unit.
Page 593 2001 NEON 21s - 78 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) (6) Remove oil filter (Fig. 11). (9) Using a screwdriver, push park rod rollers away from guide bracket (Fig. 13) and remove valve body assembly (Fig. 14). Fig. 13 Push Park Rod Rollers from Guide Bracket Fig.
Page 594 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 79 41TE AUTOMATIC TRANSAXLE (Continued) (10) Remove underdrive and overdrive accumula- tors (Fig. 15) (Fig. 16) (Fig. 17). Fig. 17 Accumulator (Overdrive) 1 - ACCUMULATOR PISTON (OVERDRIVE) Fig. 15 Remove Underdrive and Overdrive 2 - RETURN SPRING 3 - SEAL RING Accumulators...
Page 595 2001 NEON 21s - 80 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) (12) Remove low/reverse accumulator plug (Fig. 19). Fig. 21 Remove Low/Reverse Accumulator 1 - ACCUMULATOR PISTON 2 - SEAL RINGS Fig. 19 Remove Low/Reverse Accumulator Plug 3 - RETURN SPRINGS (Cover) 4 - (NOTE NOTCH) 1 - ADJUSTABLE PLIERS...
Page 596 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 81 41TE AUTOMATIC TRANSAXLE (Continued) (16) Remove oil pump-to-case bolts (Fig. 23). (18) Remove oil pump assembly (Fig. 25) (Fig. 26). Fig. 23 Remove Pump Attaching Bolts Fig. 25 Remove Oil Pump 1 - PUMP ATTACHING BOLTS 1 - “PUSH IN”...
Page 597 2001 NEON 21s - 82 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) (21) Remove #1 needle bearing (Fig. 29). Fig. 27 Remove Oil Pump Gasket 1 - PUMP GASKET Fig. 29 Remove Caged Needle Bearing 1 - #1 CAGED NEEDLE BEARING (20) Remove cooler bypass valve (Fig.
Page 598 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 83 41TE AUTOMATIC TRANSAXLE (Continued) (23) Remove #4 thrust plate (Fig. 31). (25) Remove front carrier and rear annulus assem- bly (Fig. 33). Fig. 31 No. 4 Thrust Plate 1 - OVERDRIVE SHAFT ASSEMBLY Fig.
Page 599 2001 NEON 21s - 84 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) (27) Setup tool 5058 as shown in (Fig. 35). Com- (29) Remove 2/4 clutch return spring (Fig. 37). press 2/4 clutch return spring (just enough to remove snap ring) and remove snap ring. Fig.
Page 600 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 85 41TE AUTOMATIC TRANSAXLE (Continued) (31) Remove tapered snap ring (Fig. 39). (33) Remove one low/reverse clutch disc (Fig. 41). Fig. 39 Remove Tapered Snap Ring Fig. 41 Remove One Disc 1 - LOW/REVERSE CLUTCH REACTION PLATE 1 - ONE DISC FROM LOW/REVERSE CLUTCH 2 - SCREWDRIVER 3 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)
Page 601 2001 NEON 21s - 86 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) (35) Remove low/reverse clutch pack (Fig. 43). (37) Remove transfer gear cover (Fig. 45). Fig. 43 Remove Low/Reverse Clutch Pack Fig. 45 Remove Rear Cover 1 - CLUTCH PLATES (5) 1 - REAR COVER 2 - CLUTCH DISCS (5) 2 - 1/8 INCH BEAD OF MOPAR SILICONE RUBBER ADHESIVE...
Page 602 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 87 41TE AUTOMATIC TRANSAXLE (Continued) (40) Remove transfer gear shim (select) (Fig. 49). Fig. 47 Transfer Shaft Gear Nut and Coned Washer 1 - TRANSFER SHAFT Fig. 49 Remove Transfer Shaft Gear and (Select) 2 - LOCK WASHER Shim 3 - NUT...
Page 603 2001 NEON 21s - 88 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) (42) Remove transfer gear bearing cone using (44) Using Tool 6051, remove transfer shaft bear- setup shown in (Fig. 51). ing snap ring (Fig. 53). Fig. 53 Remove Transfer Shaft Bearing Snap Ring Fig.
Page 604 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 89 41TE AUTOMATIC TRANSAXLE (Continued) (46) Slip bearing cup retainer and oil baffle off of (48) Bend output gear retaining strap ears flat to shaft (Fig. 55). allow bolt removal. (49) Remove output shaft stirrup strap bolts (Fig. 57).
Page 605 2001 NEON 21s - 90 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) (51) Using Tool 6259 (Fig. 59), remove output shaft (52) Using Tool L4407A, and button 6055, remove gear-to-shaft bolt and washer (Fig. 60). output gear from shaft (Fig. 61). Fig.
Page 606 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 91 41TE AUTOMATIC TRANSAXLE (Continued) (54) Using setup as shown in (Fig. 63), remove (56) Remove rear carrier assembly bearing cone output gear bearing cone. using setup shown in (Fig. 65). Fig. 63 Remove Bearing Cone Fig.
Page 607 2001 NEON 21s - 92 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) (59) Remove low/reverse spring compressor tool and low reverse piston return spring (Fig. 69). Fig. 67 Compressor Tool in Use 1 - LOW/REVERSE CLUTCH RETURN SPRING 2 - SNAP RING (INSTALL AS SHOWN) Fig.
Page 608 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 93 41TE AUTOMATIC TRANSAXLE (Continued) (61) Using ordinary pliers, remove pivot shaft and (63) Remove low/reverse clutch piston (Fig. 73). guide bracket assembly (Fig. 71). Fig. 73 Remove Low/Reverse Clutch Piston Fig. 71 Pivot Shaft and Guide Bracket 1 - LOW/REVERSE CLUTCH PISTON 2 - D-RING SEAL 1 - ANTIRACHET SPRING...
Page 609 2001 NEON 21s - 94 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) (65) Remove low/reverse piston retainer (Fig. 75). (67) Using a hammer and suitable drift, drive out inner output bearing cup (Fig. 77). Fig. 75 Remove Piston Retainer Fig. 77 Remove Output Bearing Inner Cup 1 - LOW/REVERSE CLUTCH PISTON RETAINER 2 - GASKET 1 - OUTPUT BEARING CUPS (REPLACE IN PAIRS)
Page 610 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 95 41TE AUTOMATIC TRANSAXLE (Continued) ASSEMBLY (2) Install low/reverse piston retainer gasket (Fig. 80). Make sure gasket holes line up with case. CAUTION: If transaxle failure has occurred, it is necessary to flush the transaxle oil cooler and lines to remove debris and particles that could contami- nate and/or fail a new or rebuilt unit.
Page 611 2001 NEON 21s - 96 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) (4) Install low/reverse piston retainer-to-case bolts (6) Assemble park guide bracket assembly (Fig. (Fig. 82) and torque to 5 N·m (45 in. lbs.). 85) (Fig. 84). Fig. 82 Install Piston Retainer Attaching Screws 1 - LOW/REVERSE CLUTCH PISTON RETAINER 2 - SCREWDRIVER Fig.
Page 612 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 97 41TE AUTOMATIC TRANSAXLE (Continued) (7) Install guide bracket into position and insert (9) Install low/reverse piston return spring (Fig. pivot shaft (Fig. 86). 88). Fig. 88 Low/Reverse Piston Return Spring Fig. 86 Pivot Shaft and Guide Bracket 1 - LOW/REVERSE PISTON RETURN SPRING 1 - ANTIRACHET SPRING 2 - PISTON...
Page 613 2001 NEON 21s - 98 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) (12) Install rear carrier assembly to transaxle case (Fig. 92). Fig. 90 Install Snap Ring 1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN) Fig. 92 Install Rear Carrier Assembly 2 - SNAP RING PLIERS 3 - TOOL 6057 1 - REAR CARRIER ASSEMBLY...
Page 614 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 99 41TE AUTOMATIC TRANSAXLE (Continued) (14) OUTPUT GEAR BEARING ADJUST- MENT: (a) With output gear removed, install a 4.50 mm (0.177 in.) gauging shim (Fig. 95) on the rear car- rier assembly hub, using grease to hold the shim in place.
Page 615 2001 NEON 21s - 100 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) OUTPUT GEAR BEARING SHIM CHART End Play Shim Needed Part Number End Play Shim Needed Part Number 0.05mm 4.42mm 0.53mm 3.94mm 4412830AB 4412818AB (0.002 in.) (0.174 in.) (0.021 in.) (0.155 in.) 0.08mm 4.38mm...
Page 616 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 101 41TE AUTOMATIC TRANSAXLE (Continued) (15) Install the output gear and bearing assembly using Tool 6261 (Fig. 96). Fig. 98 Tighten Output Gear to 271 N • m (200 ft. lbs.) 1 - OUTPUT GEAR Fig.
Page 617 2001 NEON 21s - 102 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) (18) Install output gear stirrup with serrated side (21) Rotate stirrup clockwise against flats of out (Fig. 100). retaining bolt (Fig. 102). Fig. 102 Turn Stirrup Clockwise Against Bolt Flats Fig.
Page 618 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 103 41TE AUTOMATIC TRANSAXLE (Continued) (23) Bend tabs on strap up against flats of bolts (25) Install bearing cup and oil baffle to transfer (Fig. 104). shaft (Fig. 106). Fig. 104 Bend Tabs On Strap Up Against Flats Of Fig.
Page 619 2001 NEON 21s - 104 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) (27) Using Tool 6051, install transfer shaft bearing (29) Install bearing cup retainer to transaxle (Fig. snap ring (Fig. 108). 110). Fig. 108 Install Transfer Shaft Bearing Snap Ring Fig.
Page 620 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 105 41TE AUTOMATIC TRANSAXLE (Continued) (31) TRANSFER GEAR BEARING ADJUST- MENT: (a) Install a 4.66 mm (0.184 in.) gauging shim on the transfer shaft (Fig. 112). (b) Install transfer shaft gear using Tool 6261. Using Tool 6259, install transfer shaft gear retain- ing nut to 271 N·m (200 ft.
Page 621 2001 NEON 21s - 106 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) End Play Shim Needed Part Number End Play Shim Needed Part Number 0.36mm 4.34mm 1.07mm 3.62mm 4412828AB 4412810AB (0.014 in.) (0.171 in.) (0.042 in.) (0.143 in.) 0.38mm 4.30mm 1.08mm 3.62mm 4412827AB...
Page 622 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 107 41TE AUTOMATIC TRANSAXLE (Continued) (32) Install the transfer shaft gear using Tool 6261 (35) Measure transfer shaft end play. Transfer (Fig. 113). shaft end play should be within 0.05-0.10 mm (0.002-0.004 in.). If the end play is too high, install a 0.04 mm (0.0016 in.) thicker shim.
Page 623 2001 NEON 21s - 108 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) (38) Install low/reverse clutch pack (Fig. 117). (40) Install remaining low/reverse clutch disc (Fig. Leave uppermost disc out until snap ring is installed. 119). Fig. 117 Install Low/Reverse Clutch Pack Fig.
Page 624 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 109 41TE AUTOMATIC TRANSAXLE (Continued) (42) Install tapered snap ring (with tapered side out) as shown in (Fig. 121) (Fig. 122). Fig. 123 Check Low/Reverse Clutch Clearance 1 - DIAL INDICATOR 2 - DIAL INDICATOR TIP TOOL 6268 3 - HOOK TOOL LOW/REVERSE REACTION PLATE CHART PART NUMBER...
Page 625 2001 NEON 21s - 110 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) Fig. 125 Stagger 2/4 Clutch Plate Pads Fig. 127 2/4 Clutch Retainer 1 - PILOT PADS 1 - 2/4 CLUTCH RETAINER 2 - LUGS 2 - 2/4 CLUTCH RETURN SPRING (45) Orient 2/4 clutch return spring to retainer as (46) Using tool 5058, compress 2/4 clutch return shown in (Fig.
Page 626 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 111 41TE AUTOMATIC TRANSAXLE (Continued) (47) Install snap ring. (50) Install front carrier/rear annulus assembly (48) Set up dial indicator as shown in (Fig. 129) and #6 needle bearing (Fig. 131). and measure 2/4 clutch clearance. Press down on clutch pack with finger and zero dial indicator.
Page 627 2001 NEON 21s - 112 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) (52) DETERMINING THRUST PLATE THICKNESS / INPUT SHAFT END PLAY: (a) Select the thinnest #4 thrust plate thickness and install to input clutch assembly (Fig. 133). Use petrolatum to retain. (b) Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole.
Page 628 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 113 41TE AUTOMATIC TRANSAXLE (Continued) (53) Install input clutch assembly (Fig. 137). Fig. 137 Install Input Clutch Assembly 1 - INPUT CLUTCH ASSEMBLY 2 - #4 THRUST WASHER Fig. 136 Measure Input Shaft End Play Using End Play Set 8266 (54) Install #1 caged needle bearing (Fig.
Page 629 2001 NEON 21s - 114 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) (55) Install cooler bypass valve with o-ring end (57) Install oil pump assembly (Fig. 141). towards rear of case (Fig. 139). Fig. 141 Install Oil Pump Fig. 139 Install Cooler Bypass Valve 1 - OIL PUMP 1 - COOLER BYPASS VALVE 2 - GASKET...
Page 630 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 115 41TE AUTOMATIC TRANSAXLE (Continued) (59) Install low/reverse accumulator (Fig. 143). (61) Install low/reverse accumulator snap ring (Fig. 145). Fig. 143 Install Low/Reverse Accumulator 1 - ACCUMULATOR PISTON Fig. 145 Install Low/Reverse Accumulator Snap 2 - SEAL RINGS Ring 3 - RETURN SPRINGS...
Page 631 2001 NEON 21s - 116 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) (63) Install valve body to transaxle (Fig. 149). Rotate manual valve shaft fully clockwise to ease installation. Make sure park rod rollers are posi- tioned within park guide bracket. Fig.
Page 632 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 117 41TE AUTOMATIC TRANSAXLE (Continued) (65) Install oil filter and new o-ring (Fig. 151). Fig. 151 Install Oil Filter 1 - OIL FILTER Fig. 153 Solenoid/Pressure Switch Assembly and 2 - O-RING Gasket 1 - SOLENOID/PRESSURE SWITCH ASSEMBLY (66) Apply an 1/8”...
Page 633 2001 NEON 21s - 118 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) (70) Install and torque input and output speed Torque brace-to-intake manifold bolt to 28 N·m (200 sensors to case to 27 N·m (20 ft. lbs.). in. lbs.). (10) Install structural collar. INSTALLATION (11) Install power steering oil cooler.
Page 634 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 119 41TE AUTOMATIC TRANSAXLE (Continued) SCHEMATICS AND DIAGRAMS 41TE TRANSAXLE HYDRAULIC SCHEMATICS...
Page 635 2001 NEON 21s - 120 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued)
Page 636 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 121 41TE AUTOMATIC TRANSAXLE (Continued)
Page 637 2001 NEON 21s - 122 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued)
Page 638 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 123 41TE AUTOMATIC TRANSAXLE (Continued)
Page 639 2001 NEON 21s - 124 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued)
Page 640 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 125 41TE AUTOMATIC TRANSAXLE (Continued)
Page 641 2001 NEON 21s - 126 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued)
Page 642 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 127 41TE AUTOMATIC TRANSAXLE (Continued)
Page 643 2001 NEON 21s - 128 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued)
Page 644 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 129 41TE AUTOMATIC TRANSAXLE (Continued)
Page 645 2001 NEON 21s - 130 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued)
Page 646 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 131 41TE AUTOMATIC TRANSAXLE (Continued)
Page 647 2001 NEON 21s - 132 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) SPECIFICATIONS SPECIFICATIONS - 41TE TRANSAXLE GENERAL SPECIFICATIONS DESCRIPTION SPECIFICATION Fully adaptive, electronically controlled, four speed Transaxle Type automatic with torque converter and integral differential Cooling Method Oil-to-Water Heat Exhanger Lubrication Pump (internal-external gear-type GEAR RATIOS...
Page 648 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 133 41TE AUTOMATIC TRANSAXLE (Continued) INPUT SHAFT DESCRIPTION METRIC SPECIFICATION End Play 0.127-0.635mm 0.005-0.025 in. TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Bolt, Differential — Cover-to-Case Bolt, Differential Ring — Gear-to-Case Bolt, Differential Bearing —...
Page 649 2001 NEON 21s - 134 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) SPECIAL TOOLS 41TE AUTOMATIC TRANSAXLE Seal Puller C-3981B Puller C-637 Universal Handle C-4171 Pressure Gauge (High) C-3293SP Dial Indicator C-3339 Seal Installer C-4193A Oil Pump Puller C-3752 Adapter C-4996...
Page 650 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 135 41TE AUTOMATIC TRANSAXLE (Continued) Remover Kit L-4406 Bearing Puller L-4435 Gear Puller L-4407A Differential Tool L-4436A Bearing Installer L-4410 Special Jaw Set L-4518 Gear Checking Plate L-4432 Installer L-4520...
Page 651 2001 NEON 21s - 136 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) Thrust Button L-4539-2 Puller Set 5048 Adapter L—4559 Remover/Installer 5049-A Adapter L-4559-2 Installer 5050A Bearing Splitter P-334 Installer 5052...
Page 652 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 137 41TE AUTOMATIC TRANSAXLE (Continued) Compressor 5058A Installer 6052 Compressor 5059-A Installer 6053 Installer 5067 Button 6055 Pliers 6051 Plate 6056...
Page 653 2001 NEON 21s - 138 41TE AUTOMATIC TRANSAXLE 41TE AUTOMATIC TRANSAXLE (Continued) Disk 6057 Bolt 6260 Installer 6061 Installer 6261 Remover 6062-A Tip 6268 Holder 6259 Remover/Installer 6301...
Page 654 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 139 41TE AUTOMATIC TRANSAXLE (Continued) Remover/Installer 6302 End Play Socket Set 8266 Installer 6536-A Input Clutch Pressure Fixture 8391 Cooler Flusher 6906A Puller 7794-A...
Page 655 2001 NEON 21s - 140 41TE AUTOMATIC TRANSAXLE ACCUMULATOR DESCRIPTION The 41te underdrive, overdrive, low/reverse, and 2/4 clutch hydraulic circuits each contain an accumu- lator. An accumulator typically consists of a piston, seals, return spring(s), and a cover or plug. The over- drive and underdrive accumulators are located within the transaxle case, and are retained by the valve body (Fig.
Page 656 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 141 UNDERDRIVE CLUTCH DRIVING CLUTCHES The underdrive clutch is hydraulically applied in first, second, and third (direct) gears by pressurized DESCRIPTION fluid against the underdrive piston. When the under- Three hydraulically applied input clutches are used drive clutch is applied, the underdrive hub drives the to drive planetary components.
Page 657 2001 NEON 21s - 142 41TE AUTOMATIC TRANSAXLE FINAL DRIVE (Continued) OPERATION The differential assembly is driven by the transfer shaft by way of the differential ring gear. The ring gear drives the differential case, and the case drives the driveshafts through the differential gears. The differential pinion and side gears are supported in the case by thrust washers and a pinion shaft.
Page 658 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 143 FINAL DRIVE (Continued) Fig. 165 Checking Side Gear End Play (Ring Gear Fig. 163 Remove Bearing Retainer Side) 1 - DIFFERENTIAL BEARING RETAINER 1 - SPECIAL TOOL C-4996 (NOTE POSITION) 2 - TOOL L-4435 2 - DIAL INDICATOR SET 3 - DIFFERENTIAL ASSEMBLY (3) Using a plastic hammer, remove extension...
Page 659 2001 NEON 21s - 144 41TE AUTOMATIC TRANSAXLE FINAL DRIVE (Continued) (9) Using Miller Special Tool 6062A, remove the differential bearing race from the bearing retainer (Fig. 169) (Fig. 170). Fig. 167 Position Tool 5048 Over Button and Collets at Differential Bearing (Ring Gear Side) 1 - SPECIAL TO0L 5048 Fig.
Page 660 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 145 FINAL DRIVE (Continued) DIFFERENTIAL SERVICE TOOLS COMPONENT REMOVER INSTALLER Diff. Bear. On 5048, 5048-4 5052, C-4171 Retainer Side Collets, L-4539-2 Button Diff. Bear. On 5048, 5048-3 L-4410, C-4171 Ext. Hous. Side Collets, L-4539-2 Button Diff.
Page 661 2001 NEON 21s - 146 41TE AUTOMATIC TRANSAXLE FINAL DRIVE (Continued) (8) Install extension housing/adapter plate with a FLUID bead of Mopar Silicone Rubber Adhesive Sealant and torque bolts to 28 N·m (250 in. lbs.). FLUID LEVEL AND CONDITION CHECK (9) Install differential cover with a bead of Mopar Silicone Rubber Adhesive Sealant (Fig.
Page 662 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 147 FLUID (Continued) FLUID CONDITION (1) Start engine and apply parking brake. (2) Hook up DRB scan tool and select transmis- Along with fluid level, it is important to check the sion. condition of the fluid. When the fluid smells burned, (3) Select sensors.
Page 663 2001 NEON 21s - 148 41TE AUTOMATIC TRANSAXLE FLUID (Continued) STANDARD PROCEDURE - FLUID AND FILTER (4) Clean the oil pan and magnet. Reinstall pan using new Mopar Silicone Adhesive sealant. Tighten SERVICE oil pan bolts to 19 N·m (165 in. lbs.). (5) Pour four quarts of Mopar ATF+4 (Automatic NOTE: Refer to the maintenance schedules in Transmission Fluid) Type 9602 through the dipstick...
Page 664 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 149 FLUID (Continued) NOTE: Verify that the suction line is inserted to the (2) Remove the center console assembly as shown lowest point of the transaxle oil pan. This will in (Fig. 181). ensure complete evacuation of the fluid in the pan.
Page 665 2001 NEON 21s - 150 41TE AUTOMATIC TRANSAXLE GEARSHIFT CABLE (Continued) (4) Disconnect shift cable from shifter assembly as shown in (Fig. 183). (5) Remove three grommet plate to floor pan nuts as shown in (Fig. 183). Fig. 184 Air Cleaner Assembly Removal/Installation Fig.
Page 666 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 151 GEARSHIFT CABLE (Continued) (4) Install catalytic converter heat shield (Fig. 186). (5) Install gear shift cable to bracket and connect to shift lever (Fig. 185). (6) Install and tighten the three grommet plate-to- floor pan nuts.
Page 667 2001 NEON 21s - 152 41TE AUTOMATIC TRANSAXLE GEARSHIFT CABLE (Continued) (c) Verify throttle body duct is fully seated to intake manifold and tighten clamp to 5 N·m (40 in. lbs.) torque. (d) Connect the Throttle Position Sensor (TPS) and Idle Air Control (IAC) connectors. (e) Connect proportional purge solenoid (PPS) and crankcase vent hose from throttle body.
Page 668 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 153 HOLDING CLUTCHES (Continued) Fig. 191 Gearshift Cable Adjustment Screw Fig. 192 2/4 and Low/Reverse Clutches 1 - GEARSHIFT CABLE ADJUSTMENT SCREW 1 - FRONT PLANET CARRIER/REAR ANNULUS 2 - 2/4 CLUTCH 3 - L/R CLUTCH 2/4 CLUTCH 4 - REAR PLANET CARRIER/FRONT ANNULUS The 2/4 clutch is hydraulically applied in second...
Page 669 2001 NEON 21s - 154 41TE AUTOMATIC TRANSAXLE INPUT CLUTCH ASSEMBLY (Continued) (3) Remove reverse clutch snap ring (Fig. 194). Fig. 196 Reverse Clutch Reaction Plate 1 - REVERSE CLUTCH REACTION PLATE (INSTALL FLAT SIDE Fig. 194 Reverse Clutch Snap Ring DOWN) 1 - REACTION PLATE 2 - SCREWDRIVER...
Page 670 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 155 INPUT CLUTCH ASSEMBLY (Continued) (6) Remove the OD/Reverse reaction plate snap (8) Remove OD/Reverse reaction plate wave snap ring (Fig. 198). ring (Fig. 200). Fig. 198 OD/Reverse Reaction Plate Snap Ring Fig. 200 Waved Snap Ring 1 - OD/REVERSE PRESSURE PLATE 1 - OVERDRIVE SHAFT ASSEMBLY 2 - SCREWDRIVER...
Page 671 2001 NEON 21s - 156 41TE AUTOMATIC TRANSAXLE INPUT CLUTCH ASSEMBLY (Continued) (11) Remove the underdrive shaft assembly (Fig. 204). Fig. 202 Overdrive Clutch Pack 1 - OVERDRIVE CLUTCH PLATE 2 - OVERDRIVE SHAFT ASSEMBLY Fig. 204 Underdrive Shaft Assembly 3 - OVERDRIVE CLUTCH DISC 1 - #3 THRUST WASHER (5 TABS) 2 - UNDERDRIVE SHAFT ASSEMBLY...
Page 672 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 157 INPUT CLUTCH ASSEMBLY (Continued) (13) Remove the OD/UD reaction plate tapered (15) Remove the first UD clutch disc (Fig. 208). snap ring (Fig. 206). Fig. 208 Remove One UD Clutch Disc Fig. 206 OD/UD Reaction Plate Tapered Snap Ring 1 - ONE UNDERDRIVE CLUTCH DISC 1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING...
Page 673 2001 NEON 21s - 158 41TE AUTOMATIC TRANSAXLE INPUT CLUTCH ASSEMBLY (Continued) NOTE: Tag underdrive clutch pack for reassembly (19) Remove spring retainer (Fig. 212). identification. (17) Remove the UD clutch pack (Fig. 210). Fig. 212 UD Return Spring and Retainer 1 - UNDERDRIVE SPRING RETAINER 2 - SNAP RING Fig.
Page 674 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 159 INPUT CLUTCH ASSEMBLY (Continued) (21) Remove input hub tapered snap ring (Fig. 214). Fig. 216 Input Hub Removed 1 - INPUT SHAFT AND HUB ASSEMBLY 2 - INPUT CLUTCHES RETAINER Fig. 214 Input Hub Tapered Snap Ring 3 - O-RING 1 - INPUT SHAFT 4 - SEAL...
Page 675 2001 NEON 21s - 160 41TE AUTOMATIC TRANSAXLE INPUT CLUTCH ASSEMBLY (Continued) (24) Using Tool 6057 and an arbor press, compress (25) Remove input shaft to input clutch hub snap return OD/Reverse piston return spring just enough ring (Fig. 220). to remove snap ring (Fig.
Page 676 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 161 INPUT CLUTCH ASSEMBLY (Continued) ASSEMBLY (3) Using an arbor press and Tool 6057, Install OD/Reverse piston return spring and snap ring (Fig. Use petrolatum on all seals to ease assembly of 224) (Fig. 225). components.
Page 677 2001 NEON 21s - 162 41TE AUTOMATIC TRANSAXLE INPUT CLUTCH ASSEMBLY (Continued) (4) Install the OD/Reverse piston assembly to the (6) Install input hub tapered snap ring (Fig. 228). input clutch retainer as shown in (Fig. 226). Fig. 228 Install Input Hub Tapered Snap Ring Fig.
Page 678 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 163 INPUT CLUTCH ASSEMBLY (Continued) (8) Install UD piston return spring and Tool 5067 as shown in (Fig. 230). Fig. 232 Install UD Spring Retainer and Snap Ring 1 - ARBOR PRESS RAM Fig.
Page 679 2001 NEON 21s - 164 41TE AUTOMATIC TRANSAXLE INPUT CLUTCH ASSEMBLY (Continued) (11) Install the UD clutch flat snap ring (Fig. 234). Fig. 236 OD/UD Reaction Plate Fig. 234 UD Clutch Flat Snap Ring 1 - OD/UD CLUTCH REACTION PLATE (STEP SIDE DOWN) 1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING 2 - SCREWDRIVER (12) Install the last UD clutch disc (Fig.
Page 680 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 165 INPUT CLUTCH ASSEMBLY (Continued) Fig. 238 Seating Tapered Snap Ring 1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING 2 - SCREWDRIVER Fig. 240 Set Up Dial Indicator to Measure UD Clutch Clearance 1 - DIAL INDICATOR 2 - UNDERDRIVE CLUTCH...
Page 681 2001 NEON 21s - 166 41TE AUTOMATIC TRANSAXLE INPUT CLUTCH ASSEMBLY (Continued) (20) If necessary, select the proper reaction plate to achieve specifications: UNDERDRIVE REACTION PLATE THICKNESS 4659939AB 5.837-5.937 mm (0.230-0.234 in.) 4659940AB 6.147-6.248 mm (0.242-0.246 in.) 4659941AB 6.457-6.557 mm (0.254-0.258 in.) (21) Install the OD clutch pack (four frictions/three steels) (Fig.
Page 682 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 167 INPUT CLUTCH ASSEMBLY (Continued) Fig. 248 Install Reaction Plate 1 - REVERSE CLUTCH REACTION PLATE (FLAT SIDE DOWN) Fig. 246 Measure OD Clutch Pack Clearance 1 - DIAL INDICATOR 2 - OD/REVERSE REACTION PLATE (28) Install reverse clutch pack (two frictions/one steel) (Fig.
Page 683 2001 NEON 21s - 168 41TE AUTOMATIC TRANSAXLE INPUT CLUTCH ASSEMBLY (Continued) Fig. 250 Pry Up Reaction Plate to Seat Against Snap Ring 1 - SCREWDRIVER 2 - SNAP RING 3 - SCREWDRIVER 4 - MUST RAISE REVERSE REACTION PLATE TO RAISE SNAP Fig.
Page 684 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 169 INPUT CLUTCH ASSEMBLY (Continued) (38) Install the underdrive shaft assembly (Fig. (40) Install the #3 thrust plate to the bottom of the 254). overdrive shaft assembly. Retain with petrolatum or transmission assembly gel (Fig. 256). Fig.
Page 685 2001 NEON 21s - 170 41TE AUTOMATIC TRANSAXLE OIL PUMP Verify that transmission fluid is at the proper level. If adding fluid is necessary, fill to the proper level with Mopar ATF+4 (Automatic Transmission DESCRIPTION Fluid–Type 9602). The following procedure is to The oil pump is located in the pump housing inside check oil pump output volume: the bell housing of the transaxle case (Fig.
Page 686 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 171 OIL PUMP (Continued) DISASSEMBLY When disassembling the transaxle it is necessary to inspect the oil pump for wear and damage. (1) Remove the reaction shaft support bolts. (2) Remove reaction shaft support from pump housing (Fig.
Page 687 2001 NEON 21s - 172 41TE AUTOMATIC TRANSAXLE OIL PUMP (Continued) ASSEMBLY (1) Assemble oil pump as shown in (Fig. 263) (2) Install and torque reaction shaft support-to-oil pump housing bolts to 28 N·m (20 ft. lbs.) torque. Fig. 264 Planetary Geartrain 1 - FRONT SUN GEAR ASSEMBLY 2 - #6 THRUST BEARING 3 - #7 THRUST BEARING...
Page 688 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 173 SEAL - OIL PUMP (Continued) INSTALLATION (1) Using Tool C-4193, install oil pump seal (Fig. 266). Fig. 267 Gearshift Knob Removal/Installation 1 - SHIFTER KNOB Fig. 266 Install Oil Pump Seal 2 - SET SCREW 1 - TOOL C-4193 2 - HANDLE TOOL C-4171 (2) Install transaxle to vehicle (Refer to 21 -...
Page 689 2001 NEON 21s - 174 41TE AUTOMATIC TRANSAXLE SHIFT INTERLOCK CABLE (Continued) Fig. 271 Steering Column Lower Cover 1 - LOWER COVER Fig. 269 Shifter Bezel Removal/Installation (7) Remove the steering column upper and lower 1 - BEZEL shrouds (Fig. 272). 2 - SCREW (4) Fig.
Page 690 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 175 SHIFT INTERLOCK CABLE (Continued) Fig. 275 Interlock 1 - IGNITION LOCK CYLINDER 2 - INTERLOCK CABLE INSTALLATION Fig. 273 Interlock Cable at Steering Column CAUTION: When installing interlock cable assembly, care must be taken not to bend exposed cable wire 1 - IGNITION SWITCH 2 - CLIP and slug at shifter end of cable.
Page 691 2001 NEON 21s - 176 41TE AUTOMATIC TRANSAXLE SHIFT INTERLOCK CABLE (Continued) (4) Return the ignition key to the “LOCK” position SHIFT INTERLOCK (Fig. 274). MECHANISM (5) Connect the BTSI solenoid connector (Fig. 273). (6) Install cable into retaining clips as shown in REMOVAL (Fig.
Page 692 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 177 SHIFT INTERLOCK MECHANISM (Continued) (3) Turn the ignition key to the “OFF” or “ON/ RUN” position (Fig. 279). Fig. 281 Interlock Mechanism Fig. 279 Ignition Key/Switch Positions 1 - MOUNTING SCREW 1 - ACC 2 - INTERLOCK MECHANISM 2 - LOCK 3 - OFF...
Page 693 2001 NEON 21s - 178 41TE AUTOMATIC TRANSAXLE SHIFT INTERLOCK SYSTEM (Continued) ADJUSTMENT ACTION EXPECTED RESPONSE (1) Loosen set screw and remove knob from shifter 1. Turn key to the OFF 1. Shifter CAN be shifted handle (Fig. 282). position. out of park.
Page 694 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 179 SHIFT INTERLOCK SYSTEM (Continued) (3) Remove shifter bezel (Fig. 284). Fig. 284 Shifter Bezel Removal/Installation 1 - BEZEL Fig. 285 Solenoid/Pressure Switch Assembly 2 - SCREW (4) 1 - SOLENOID AND PRESSURE SWITCH ASSEMBLY (4) Adjust interlock cable/system as follow- s:Pry up on cable adjuster lock to release and allow OPERATION...
Page 695 2001 NEON 21s - 180 41TE AUTOMATIC TRANSAXLE SOLENOID/PRESSURE SWITCH ASSY (Continued) ing and opening points is 11-23 psi. Typically the (4) Disconnect input speed sensor connector. switch opening point will be approximately one psi (5) Remove input speed sensor (Fig. 286). lower than the closing point.
Page 696 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 181 SOLENOID/PRESSURE SWITCH ASSY (Continued) (7) Remove solenoid/pressure switch assembly and SPEED SENSOR - INPUT gasket (Fig. 288). Use care to prevent gasket mate- rial and foreign objects from become lodged in the DESCRIPTION transaxle case ports.
Page 697 2001 NEON 21s - 182 41TE AUTOMATIC TRANSAXLE SPEED SENSOR - INPUT (Continued) OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil (Fig. 291), an AC voltage is generated and sent to the TCM.
Page 698 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 183 OPERATION SPEED SENSOR - OUTPUT The Output Speed Sensor provides information on DESCRIPTION how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor The Output Speed Sensor is a two-wire magnetic coil (Fig.
Page 699 2001 NEON 21s - 184 41TE AUTOMATIC TRANSAXLE SPEED SENSOR - OUTPUT (Continued) TORQUE CONVERTER DESCRIPTION The torque converter (Fig. 299) is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine, a stator, an overrunning clutch, an impeller and an electronically applied converter clutch.
Page 700 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 185 TORQUE CONVERTER (Continued) IMPELLER The impeller (Fig. 300) is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the con- verter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving member of the system.
Page 701 2001 NEON 21s - 186 41TE AUTOMATIC TRANSAXLE TORQUE CONVERTER (Continued) TURBINE The turbine (Fig. 301) is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine.
Page 702 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 187 TORQUE CONVERTER (Continued) STATOR The stator assembly (Fig. 302) is mounted on a sta- tionary shaft which is an integral part of the oil pump. The stator is located between the impeller and turbine within the torque converter case (Fig.
Page 703 2001 NEON 21s - 188 41TE AUTOMATIC TRANSAXLE TORQUE CONVERTER (Continued) Fig. 305 Torque Converter Fluid Operation 1 - APPLY PRESSURE 3 - RELEASE PRESSURE 2 - THE PISTON MOVES SLIGHTLY FORWARD 4 - THE PISTON MOVES SLIGHTLY REARWARD that was hitting the stator in such as way as to TURBINE cause it to lock–up is no longer doing so.
Page 704 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 189 TORQUE CONVERTER (Continued) TORQUE CONVERTER CLUTCH (TCC) Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and In a standard torque converter, the impeller and notches with 320/400 grit paper or crocus cloth if nec- turbine are rotating at about the same speed and the essary.
Page 705 2001 NEON 21s - 190 41TE AUTOMATIC TRANSAXLE TORQUE CONVERTER (Continued) (10) If torque conveter was replaced, it is neces- TRANSMISSION RANGE sary to reset the TCC Break-In Strategy. (Refer to 8 - SENSOR ELECTRICAL/ELECTRONIC CONTROL MOD- ULES/TRANSMISSION CONTROL MODULE DESCRIPTION STANDARD PROCEDURE) The Transmission Range Sensor (TRS) is mounted...
Page 706 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 191 TRANSMISSION RANGE SENSOR (Continued) CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a pre- dicted fluid temperature which is calculated from a combination of inputs: •...
Page 707 2001 NEON 21s - 192 41TE AUTOMATIC TRANSAXLE REGULATOR VALVE TRD LINK The regulator valve controls hydraulic pressure in the transaxle. It receives unregulated pressure from DESCRIPTION the pump, which works against spring tension to The Torque Reduction Link (TRD) is a wire maintain oil at specific pressures.
Page 708 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 193 VALVE BODY (Continued) Fig. 312 Valve Body Assembly 1 - VALVE BODY 5 - MANUAL VALVE 2 - T/C REGULATOR VALVE 6 - CONVERTER CLUTCH SWITCH VALVE 3 - L/R SWITCH VALVE 7 - SOLENOID SWITCH VALVE 4 - CONVERTER CLUTCH CONTROL VALVE 8 - REGULATOR VALVE...
Page 709 2001 NEON 21s - 194 41TE AUTOMATIC TRANSAXLE VALVE BODY (Continued) (8) Remove oil pan (Fig. 314). Fig. 314 Oil Pan 1 - OIL PAN Fig. 316 Valve Body Attaching Bolts 2 - 1/8 INCH BEAD OF RTV SEALANT 1 - VALVE BODY ATTACHING BOLTS (18) 3 - OIL FILTER 2 - VALVE BODY (9) Remove oil filter (Fig.
Page 710 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 195 VALVE BODY (Continued) (2) Remove Transmission Range Sensor retaining screw (Fig. 320). Fig. 318 Valve Body Removal/Installation 1 - VALVE BODY DISASSEMBLY Fig. 320 Remove Transmission Range Sensor NOTE: If valve body assembly is being recondi- 1 - TRANSMISSION RANGE SENSOR tioned, the TCM Quick Learn Procedure must be 2 - MANUAL VALVE CONTROL PIN...
Page 711 2001 NEON 21s - 196 41TE AUTOMATIC TRANSAXLE VALVE BODY (Continued) (4) Remove 2/4 Accumulator Retaining Plate (Fig. (6) Remove Valve Body to Transfer Plate screws 322). (Fig. 324). Fig. 322 2/4 Accumulator Retaining Plate 1 - 2–4 ACCUMULATOR RETAINING PLATE 2 - DETENT SPRING Fig.
Page 712 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 197 VALVE BODY (Continued) (8) Remove oil screen (Fig. 326). Fig. 328 Remove Separator Plate 1 - SEPARATOR PLATE Fig. 326 Remove Oil Screen 2 - VALVE BODY 1 - OIL SCREEN (11) Remove thermal valve (Fig. 329). (9) Remove the overdrive clutch (#5) check valve (Fig.
Page 713 2001 NEON 21s - 198 41TE AUTOMATIC TRANSAXLE VALVE BODY (Continued) Fig. 330 Ball Check Location 1 - (#4) BALL CHECK LOCATION 4 - (#3) BALL CHECK LOCATION 2 - (#2) BALL CHECK LOCATION 5 - LOW/REVERSE SWITCH VALVE 3 - RETAINER 6 - T/C LIMIT VALVE NOTE: Tag all valve/spring assemblies for reassem- bly identification.
Page 714 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 199 VALVE BODY (Continued) (15) Remove remaining retainers as shown in (Fig. (13) Remove dual retainer plate using Tool 6301 333). (Fig. 331). Fig. 333 Valve Retainer Location Fig. 331 Remove Dual Retainer Plate using Tool 1 - RETAINER 6301 2 - RETAINER...
Page 715 2001 NEON 21s - 200 41TE AUTOMATIC TRANSAXLE VALVE BODY (Continued) Fig. 334 Springs and Valves Location 1 - VALVE BODY 5 - MANUAL VALVE 2 - T/C REGULATOR VALVE 6 - CONVERTER CLUTCH SWITCH VALVE 3 - L/R SWITCH VALVE 7 - SOLENOID SWITCH VALVE 4 - CONVERTER CLUTCH CONTROL VALVE 8 - REGULATOR VALVE...
Page 716 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 201 VALVE BODY (Continued) Fig. 339 Install Thermal Valve Fig. 337 Valve Retainer Location 1 - THERMAL VALVE 1 - RETAINER 2 - RETAINER Fig. 338 Ball Check Location 1 - (#4) BALL CHECK LOCATION 4 - (#3) BALL CHECK LOCATION 2 - (#2) BALL CHECK LOCATION 5 - LOW/REVERSE SWITCH VALVE...
Page 717 2001 NEON 21s - 202 41TE AUTOMATIC TRANSAXLE VALVE BODY (Continued) (6) Install thermal valve into transfer plate (Fig. (9) Install oil screen to separator plate (Fig. 342). 339). (7) Install separator plate to valve body (Fig. 340). Fig. 342 Install Oil Screen 1 - OIL SCREEN Fig.
Page 718 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 203 VALVE BODY (Continued) (11) Install twenty-four transfer plate to valve (13) Torque 2/4 Accumulator retainer to 5 N·m (45 body screws (Fig. 344) and torque to 5 N·m (45 in. in. lbs.) (Fig. 346). lbs.).
Page 719 2001 NEON 21s - 204 41TE AUTOMATIC TRANSAXLE VALVE BODY (Continued) INSTALLATION (15) Make sure Manual Valve control pin is con- tained within the rooster comb slot (Fig. 348). Install Transmission Range Sensor retaining screw (Fig. NOTE: If valve body assembly is being replaced or 348) and torque to 5 N·m (45 in.
Page 720 2001 NEON 41TE AUTOMATIC TRANSAXLE 21s - 205 VALVE BODY (Continued) (2) Install transaxle oil filter (Fig. 352). Inspect the o-ring and replace if necessary. Fig. 353 Oil Pan 1 - OIL PAN 2 - 1/8 INCH BEAD OF RTV SEALANT 3 - OIL FILTER Fig.
Page 721 2001 NEON...
Page 722 2001 NEON BODY 23s - 1 BODY TABLE OF CONTENTS page page BODY EXTERIOR ....... 5 DESCRIPTION .
Page 723 2001 NEON 23s - 2 BODY BODY (Continued) SEATS SPECIFICATIONS Seat modules are made up of a seat frame, seat SPECIFICATIONS - LUBRICANT USAGE cushion, seat back cushion, a covering material, and the electrical components used for power operation, if equipped.
Page 724 2001 NEON BODY 23s - 3 BODY (Continued) SPECIFICATIONS - TORQUE TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. All seat belt anchor bolts — All seat belt anchor nuts — All seat belt retractor bolts — Decklid latch striker —...
Page 725 2001 NEON 23s - 4 DECKLID/HATCH/LIFTGATE/TAILGATE DECKLID/HATCH/LIFTGATE/TAILGATE TABLE OF CONTENTS page page EMERGENCY RELEASE CABLE INSTALLATION......4 REMOVAL .
Page 726 2001 NEON EXTERIOR 23s - 5 EXTERIOR TABLE OF CONTENTS page page BODY STRIPES AND DECALS INSTALLATION......5 REMOVAL .
Page 727 2001 NEON 23s - 6 EXTERIOR SPOILER REMOVAL (1) Remove the decklid cover. (Refer to 23 - BODY/ DECKLID/HATCH/LIFTGATE/TAILGATE/COVER - REMOVAL) (2) Remove the four nuts and remove the spoiler (Fig. 2). Fig. 2 SPOILER 1 - DECKLID 2 - SPOILER 3 - NUTS INSTALLATION (1) Install the spoiler and nuts.
Page 728 2001 NEON INSTRUMENT PANEL 23s - 7 INSTRUMENT PANEL TABLE OF CONTENTS page page GLOVE BOX INSTRUMENT PANEL TOP COVER REMOVAL ....... 7 REMOVAL .
Page 729 2001 NEON 23s - 8 INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY (Continued) (25) Pull HVAC control head out of instrument panel, twist 90° and push back through the opening (Fig. 3). Do not disconnect the control cables. Fig. 1 A-PILLAR DOOR HARNESS CONNECTOR 1 - INSTRUMENT PANEL HARNESS CONNECTOR 2 - DOOR CHECK STRAP 3 - DOOR HARNESS CONNECTOR...
Page 730 2001 NEON INSTRUMENT PANEL 23s - 9 INSTRUMENT PANEL ASSEMBLY (Continued) Fig. 4 INSTRUMENT PANEL ASSEMBLY 1 - INSTRUMENT PANEL ASSEMBLY 9 - BEZEL INSTRUMENT PANEL, CENTER 2 - UPPER COVER INSTRUMENT PANEL 10 - BIN, LOWER STORAGE 3 - MODULE, PASSENGER SIDE AIRBAG 11 - COVER, LOWER INSTRUMENT PANEL 4 - END CAP, RIGHT 12 - CLUSTER BEZEL...
Page 731 2001 NEON 23s - 10 INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY (Continued) (4) Pull HVAC control head out of instrument INSTRUMENT PANEL END panel, twist 90° and position in place (Fig. 3). COVER (5) Connect the one vacuum harness connector. (6) Connect the one instrument panel wire harness REMOVAL connector.
Page 732 2001 NEON INSTRUMENT PANEL 23s - 11 LOWER INSTRUMENT PANEL (3) Remove two screws retaining the top front of the center bezel up inside the center A/C outlet duct. COVER (4) Using a trim stick (special tool #C-4755) or equivalent, gently pry out on instrument panel cen- REMOVAL ter bezel.
Page 733 2001 NEON 23s - 12 INTERIOR INTERIOR TABLE OF CONTENTS page page B-PILLAR TRIM FLOOR CONSOLE REMOVAL ......12 REMOVAL .
Page 734 2001 NEON INTERIOR 23s - 13 B-PILLAR TRIM (Continued) (5) Remove screws attaching console to floor bracket. (6) Remove shift lever knob, if vehicle is equipped with a manual transmission. (7) Lift console upward over gear selector and park brake handle. (8) Remove console from vehicle.
Page 735: Table Of Contents
2001 NEON 23s - 14 SUNROOF SUNROOF TABLE OF CONTENTS page page SUNROOF DRIVE MOTOR DESCRIPTION ......14 REMOVAL .
Page 736: Diagnosis And Testing
2001 NEON SUNROOF 23s - 15 SUNROOF (Continued) Fig. 1 SUNROOF COMPONENTS Item Number Component Name Item Number Component Name Wind Deflector Frame Assembly Motor Bracket Mechanism Bracket Sunroof Headliner Trim Welt Guide Single Control Unit (SCU) Sunshade Guide Sunshade Glass Panel Drive Motor Assembly the power sunroof control switches.
Page 737 2001 NEON 23s - 16 SUNROOF SUNROOF (Continued) SYMPTOM STEP POSSIBLE CAUSE Sunroof squeaks when Identify if cause is seal squeak. If seal is worn, replace seal. opening/closing. Check seal compression for uniformity in opening. If not uniform, glass is not centered in opening. Re-center glass by repositioning module in opening.
Page 738: Limit Switch Description
2001 NEON SUNROOF 23s - 17 SUNROOF (Continued) SYMPTOM STEP POSSIBLE CAUSE Sunshade squeaks/rattles, Sunshade slide blocks out of track(s), put back in tracks. anytime. Missing felt pads on drain channel, add felt pads. -OR- Felt on drain channel rolling off, (sunshade rubs on adhesive), Sunshade force high./low or replace felt pads.
Page 739: Drive Motor Removal
2001 NEON 23s - 18 SUNROOF DRIVE MOTOR (4) Push glass panel upward from underside until glass panel clears the roof panel. (5) Lift glass panel from vehicle. REMOVAL ADJUSTMENTS – SUNROOF VENT POSITION NOTE: The Drive Motor is shipped in the VENT position.
Page 740: Sunshade Removal
2001 NEON SUNROOF 23s - 19 GLASS PANEL (Continued) (c) Tighten all glass attachment screws. CENTERING SUNROOF GLASS ADJUSTMENT Using a business card, check sunroof glass for cen- ter in opening (Fig. 5). Move business card around the glass seal, noting area where there is less pres- sure on the card.
Page 741: Wind Deflector Removal
2001 NEON 23s - 20 SUNROOF WIND DEFLECTOR (6) Repeat for other corner piece. INSTALLATION REMOVAL (1) Hold corner piece vertically and push tab down (1) Open sunroof to full open position. through hole in the sunshade guide. (2) Pull one end of wind deflector flap out of the (2) Rotate corner piece inward and place tab under wind deflector (Fig.
Page 742 SERVICE MANUAL COMMENTS What features do you find most useful? ______________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ What errors have you found? Please include page number. ___________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ What topics are hard to locate, confusing, or not covered completely? ________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________...
Page 743 DaimlerChrysler International Operations Attn. Publications Dept. CIMS 486-02-70 800 Chrysler Drive Auburn Hills, MI 48326-2757...

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