Dodge Neon 2001 Service Manual Download Page 26 | Manualshive

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(8) Remove the two remaining nuts fastening the

brake pedal bracket to the power brake booster (Fig.
11).

(9) If the vehicle is equipped with antilock brakes,

carefully push the power brake booster forward until
the booster contacts the ABS ICU mounting bracket.

(10) If the vehicle does not have antilock brakes,

carefully push the power brake booster forward one
to two inches being careful not to stretch the brake
lines from the master cylinder to the brakes.

(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. Next, tip the bracket down past the input rod,
guiding the rod through the gap left by the missing
brace removed in Step (8). Remove the brake pedal
assembly out from under the instrument panel.

(13) The pedal can be removed from it’s bracket by

grinding off the peened end of the shaft, removing
the shaft, pedal and bushings. A service parts pack-
age is available to replace these items.

WITH MANUAL TRANSAXLE

(1) Remove the instrument panel. (Refer to 23 -

BODY/INSTRUMENT

PANEL/INSTRUMENT

PANEL ASSEMBLY - REMOVAL).

(2) Remove the brake lamp switch. (Refer to 8 -

ELECTRICAL/LAMPS/LIGHTING

-

EXTERIOR/

BRAKE LAMP SWITCH - REMOVAL)

(3) Disconnect the clutch cable from the clutch

pedal spacer (Fig. 12).

(4) Disconnect the wiring harness connector going

to the clutch pedal switches (Fig. 13).

(5) Remove the clip securing the power brake

booster input rod to the brake pedal. Remove the
input rod from the brake pedal.

Fig. 10 Steering Column Couplings

1 - STEERING COLUMN UPPER COUPLING
2 - PINCH BOLT
3 - STEERING COLUMN LOWER COUPLING
4 - BRAKE PEDAL
5 - NUT
6 - RETAINER PIN

Fig. 11 Brake Pedal Mounting

1 - CLUTCH CABLE
2 - BOOSTER MOUNTING NUTS
3 - UPPER MOUNTING NUTS

Fig. 12 Clutch Cable Connection

1 - SNAP RING
2 - CLUTCH PEDAL SPACER
3 - CLUTCH PEDAL
4 - CLUTCH CABLE

PL

BRAKES-BASE

5s - 13

PEDAL (Continued)

ProCarManuals.com

2001 NEON

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Summary of Contents for Neon 2001

Page 1: ...OR 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 Pr...

Page 2: ...r Approval Number VEHICLE IDENTIFICATION NUMBER DESCRIPTION The Vehicle Identification Number VIN can be viewed through the windshield at the upper left cor ner of the instrument panel next to the lef...

Page 3: ...aimlserChrysler Corporation 2 Make C Chrysler 3 Vehicle Type 3 Passenger Car 4 Passenger Safety E Active Restraints Driver and Passenger Airbags 5 Car Line S Neon BUX L H D V Neon BUX R H D 6 Series M...

Page 4: ...dual Torque Charts appear within many or the Groups Refer to the Standard Torque Specifica tions Chart for torque references not listed in the individual torque charts TORQUE SPECIFICATIONS PL INTRODU...

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Page 6: ...ropylene Glycol based coolants is not recommended as they provide less freeze protection and less corrosion protection The cooling system is designed around the coolant The coolant must accept heat fr...

Page 7: ...rformance Light spark knock at low engine speeds is not harmful to your engine However continued heavy spark knock at high speeds can cause damage and immediate service is required Engine damage resul...

Page 8: ...d result in loss of warranty coverage An out of tune engine or certain fuel or ignition malfunctions can cause the catalytic converter to overheat If you notice a pungent burning odor or some light sm...

Page 9: ...e heat to the radiator where the tube fin radiator can transfer the heat to the air WARNING ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWAL LOWED OR INHALED IF SWALLOWED DRINK TWO...

Page 10: ...dules must be done at the mileage specified to assure the continued proper functioning of the emission control system These and all other maintenance services included in this manual should be done to...

Page 11: ...ation to the owner but is not required to maintain the emissions warranty NOTE Inspection and service should also be per formed anytime a malfunction is observed or sus pected Retain all receipts SCHE...

Page 12: ...the ignition cables Replace the spark plugs Change the automatic transaxle fluid filter and adjust bands 63 000 Miles 101 000 km Change the engine oil Replace the engine oil filter 66 000 Miles 106 0...

Page 13: ...filter Inspect the engine air cleaner element fil ter and replace as necessary This maintenance is recommended by DaimlerChrysler Corporation to the owner but is not required to maintain the emissions...

Page 14: ...MOVAL 10 INSTALLATION 11 MASTER CYLINDER RHD REMOVAL 11 INSTALLATION 12 PEDAL REMOVAL 12 INSTALLATION 14 POWER BRAKE BOOSTER RHD REMOVAL 15 INSTALLATION 16 PROPORTIONING VALVE DIAGNOSIS AND TESTING 16...

Page 15: ...Excessive brake rotor runout 1 Follow brake rotor diagnosis and testing Correct as necessary 2 Lack of lubricant on brake caliper slides 2 Lubricate brake caliper slides DISC BRAKE RATTLE OR CLUNK 1 B...

Page 16: ...y 2 Parking brake cable return spring not returning shoes 2 Replace cables as necessary 3 Service brakes not adjusted properly rear drum brakes only 3 Follow the procedure listed in the adjustment sec...

Page 17: ...2 Inoperative proportioning valve non ABS vehicles only 2 Test proportioning valves folowing procedure listed in diagnosis and testing section Replace valves as necessary 3 ABS EBD not functioning 3 R...

Page 18: ...ce the brake pedal has dropped close the bleeder screw After the bleeder screw is closed release the brake pedal 5 Repeat the above steps until all trapped air is removed from that wheel circuit usual...

Page 19: ...are W ABS Primary Tube Nut Thread 7 16 in 24 W ABS Secondary Tube Nut Thread 3 8 in 24 W O ABS All Tube Nut Threads 7 16 in 24 ABS HYDRAULIC CONTROL UNIT Hydraulic Tube Fitting Type SAE 45 Inverted Fl...

Page 20: ...th cylinder pistons The piston pressure is transmitted directly to the top of each brake shoe This forces the shoes out against the inner surface of the brake drum This causes friction bringing the ve...

Page 21: ...CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOT...

Page 22: ...S FROM PRODUCTION OR AFTERMARKET BRAKE LININGS BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM EXERCISE CARE WHEN SERVICING BRAKE PARTS DO NOT SAND OR GRIND BRAKE L...

Page 23: ...CYLINDER LHD REMOVAL NOTE Before proceeding with this procedure Refer to 5 BRAKES WARNING CAUTION The vacuum in the power brake booster must be pumped down before removing the master cylinder to preve...

Page 24: ...two master cylinder mounting nuts and tighten each to a torque of 18 N m 160 in lbs 6 Connect the four brake tubes to the master cyl inder and proportioning valve ports Fig 7 Tighten all tube nuts to...

Page 25: ...res in the STRAIGHT AHEAD position Using a steering wheel holder lock the steering wheel in place to keep it from rotating Fig 9 This keeps the clockspring in the proper orientation 3 Remove the steer...

Page 26: ...anel 13 The pedal can be removed from it s bracket by grinding off the peened end of the shaft removing the shaft pedal and bushings A service parts pack age is available to replace these items WITH M...

Page 27: ...heir studs 8 Tighten all four nuts fastening the brake pedal bracket to the power brake booster to a torque of 34 N m 300 in lbs 9 Tighten the two nuts fastening the brake pedal bracket to the instrum...

Page 28: ...e stop lamps to verify they are oper ating properly and not staying on when the pedal is in the released position 12 Road test the vehicle to ensure proper opera tion of the brakes POWER BRAKE BOOSTER...

Page 29: ...tch master cylinder in position Rotate the clutch master cylinder to line up the square shaped retaining boss with the square shaped opening in the brake pedal support bracket Once the cylinder is ins...

Page 30: ...wn to determine which pro portioning valve needs to be tested Fig 16 3 Remove the hydraulic brake tube from the pro portioning valve controlling the rear wheel of the vehicle that has premature wheel...

Page 31: ...valve Torque the tube nut to 17 N m 145 in lbs 15 Bleed the affected brake line Refer to 5 BRAKES STANDARD PROCEDURE BRAKE PROPORTIONING VALVE APPLICATIONS AND PRESSURE SPECIFICATIONS Sales Code Brak...

Page 32: ...C MECHANICAL BRAKE PADS SHOES REMOVAL 4 Remove rear brake rotor Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTORS REMOV AL 5 Remove the dust cap from the rear hub and bearing 6 Remove the rear hub and bea...

Page 33: ...e and secure it in place with a hold down clip Fig 26 2 Install the rear brake shoe and the upper shoe return spring Fig 25 Pull the rear brake shoe over the anchor block until it is properly located...

Page 34: ...mission into neutral 3 Remove the screws attaching the center con sole then remove the center console 4 Lower the parking brake lever handle to the released position 5 Grasp the parking brake lever ou...

Page 35: ...n spring both shoe hold down clips then spread the rear parking brake shoes apart at the top enough to clear the shoe anchor and remove the parking brake shoes as an assembly from the disc brake adapt...

Page 36: ...mpress the locking fingers on the parking brake cable retainer Fig 35 19 Remove the nuts then the parking brake cable routing bracket from the tension strut mount ing bolts 20 Remove the parking brake...

Page 37: ...ar tire and wheel assembly Refer to 22 TIRES WHEELS INSTALLATION Tighten all wheel nuts to a torque of 135 N m 100 ft lbs 11 Lower the vehicle 12 Ensure that the seal grommet on the cable that was ins...

Page 38: ...vehicle parking brake lever is released 2 Fully apply the parking brake lever then shift the transmission into neutral 3 Remove the screws attaching the center con sole then remove the center console...

Page 39: ...tor on the parking brake warning lamp switch Fig 38 3 Install both rear park brake cables into the equalizer on the parking brake lever output cable Fig 37 4 Ensure that the parking brake cables are c...

Page 40: ...th rear wheel solenoids receive the same electrical signal Wheel lockup may be perceived at the very end of an ABS stop and is considered nor mal During an ABS stop the brakes hydraulic system is stil...

Page 41: ...BS cycling can occur at any braking rate of the vehicle and on any type of road surface Neither the red BRAKE warning indicator lamp nor the amber ABS warning indicator lamp illuminate and no fault co...

Page 42: ...ted 6 Turn the key to the OFF position and then back to the ON position Note whether the amber ABS warning indicator lamp continues to stay on 7 If the amber ABS warning indicator lamp stays on shift...

Page 43: ...and the current sense circuit is provided by the CAB When a valley of the tone wheel is aligned with the sensor the voltage signal is approximately 0 8 volts and a constant 7 mA current is sent to th...

Page 44: ...ifts the magnetic field and the IC enables a second 7 mA current source The CAB senses a voltage signal of approxi mately 1 6 volts and 14 mA The CAB measures the amperage of the digital signal for ea...

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Page 46: ...LIC The clutch hydraulic system Fig 2 consists of a clutch master cylinder and integral reservoir a clutch slave cylinder and integral damper and an interconnecting fluid line FLUID CAUTION Never use...

Page 47: ...bearing in contact with the diaphragm spring As additional force is applied the bearing presses the diaphragm spring fingers inward on the fulcrums This action moves the pressure plate rear ward reli...

Page 48: ...OUT Normal wear Replace modular clutch assembly Driver frequently rides slips clutch results in rapid wear overheating Replace modular clutch assembly Insufficient clutch cover diaphragm spring tensio...

Page 49: ...SIS CLUTCH PEDAL NOISE CONDITION POSSIBLE CAUSES CORRECTION CLUTCH PEDAL SQUEAKS WHEN DEPRESSED TO FLOOR Pedal bushings worn out or inadequate lubrication Replace or lubricate bushings Clutch pedal re...

Page 50: ...d and fork fingers Replace all worn parts d Check clutch assembly for contamination dirt oil Replace clutch assembly if required e Check to see if the clutch disc hub splines are damaged Replace with...

Page 51: ...edal pivot shaft and remove brake and clutch pedals 11 Remove the interlock upstop switch assembly Fig 7 from the brake clutch pedal bracket assembly by depressing the four plastic wing tabs on each s...

Page 52: ...in lbs 7 Connect interlock upstop and stop lamp switch connectors 8 Install left lower instrument panel bezel Fig 4 9 Connect battery negative cable 10 Verify proper switch operation RELEASE BEARING A...

Page 53: ...and an interconnecting hydraulic tube Fig 11 OPERATION The clutch master cylinder Fig 11 produces the hydraulic pressure necessary to disengage the clutch When the clutch pedal is depressed the push...

Page 54: ...the brake pedal pin Fig 16 10 Remove the brake booster mounting nuts Fig 16 11 Slide brake booster forward enough to gain access to and remove clutch master cylinder 12 Remove clutch master cylinder...

Page 55: ...4 Route the hydraulic tube as noted upon removal 5 Connect the master cylinder hydraulic line to the slave cylinder hydraulic line An audible click should be heard Verify the connection by pulling out...

Page 56: ...the Throttle Position Sensor TPS and Idle Air Control IAC connectors c Disconnect throttle body air duct at intake manifold d Remove mounting bolt and nut Fig 20 and partially remove air cleaner asse...

Page 57: ...5 15 Remove the left engine to transaxle lateral bending brace Fig 25 16 Remove bellhousing dust cover Fig 25 17 Remove the right engine to transaxle lateral bending brace Fig 26 18 Remove starter mot...

Page 58: ...BENDING BRACE 2 STRUCTURAL COLLAR 3 DUST COVER Fig 26 Right Lateral Bending Brace Removal Installation Typical 1 TRANSAXLE 2 ENGINE 3 LATERAL BENDING BRACE Fig 27 Starter Motor Removal Installation T...

Page 59: ...65 ft lbs torque 7 Install starter motor and tighten bolts to 54 N m 40 ft lbs torque Make sure to fasten ground cable to upper starter bolt as shown in Fig 27 8 Connect starter electrical harness an...

Page 60: ...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 v...

Page 61: ...o 19 N m 170 in lbs torque 3 Tighten damper nuts to 23 N m 200 in lbs torque 4 Connect clutch hydraulic supply tube Fig 33 An audible click should be heard Verify connection by pulling outward 5 Lower...

Page 62: ...DESCRIPTION N m Ft Lbs In Lbs A C Condenser to Radiator Screws 5 4 50 Automatic Belt Tensioner Pulley Bolt 27 20 Coolant Recovery Container Nut Screw 4 35 Coolant Temperature Sensor 18 165 DESCRIPTIO...

Page 63: ...L TOOLS COOLING SYSTEM Cooling System Tester 7700 Coolant Refractometer 8286 Belt Tension Gauge Adapter 8371 DRB IIIT with PEP Module OT CH6010A 7s 2 COOLING PL COOLING Continued ProCarManuals com 200...

Page 64: ...rator belt NOTE When installing drive belt onto pulleys make sure that belt is properly routed and all V grooves make proper contact with pulley grooves INSTALLATION POWER STEERING PUMP AND AIR CONDIT...

Page 65: ...ures WARNING DO NOT CHECK BELT TENSION WITH ENGINE RUNNING a Connect 8371 to the DRBIIIt following the instructions provided with tool b Place end of microphone probe approximately 2 54 cm 1 in from b...

Page 66: ...NSION CHART Accessory Drive Belt Belt Tension Power Steering Pump A C Compressor Dynamic Tensioned Generator New 135 lbs 224 252 Hz Used 70 lbs 172 181 Hz A belt is considered used after 15 minutes of...

Page 67: ...emove hose clamp from heater return tube located near starter Disconnect hose from tube 5 Lower vehicle 6 Remove air cleaner housing and throttle body to intake manifold hose 7 Disconnect PCV vacuum h...

Page 68: ...ble from battery 2 Drain cooling system below the upper radiator hose level Refer to 7 COOLING STANDARD PROCEDURE 3 Remove the upper hose from radiator Fig 1 4 Remove the air cleaner housing and throt...

Page 69: ...oning line support bracket screw Fig 3 5 Connect radiator fan electrical connector Fig 2 6 Install powertrain control module PCM Refer to 8 ELECTRICAL ELECTRONIC CON TROL MODULES POWERTRAIN CONTROL MO...

Page 70: ...bserve the flow meter gauge Refer to the following chart for specifications COOLER FLOW SPECIFICATION Min 2 6 LPM 0 7 GPM 4 If oil flow is below minimum specifications fur ther diagnosis must be perfo...

Page 71: ...ler Flush MS 552 or equivalent solution conforming to MS 552 Flushing solvents are petroleum based solutions generally used to clean automatic transmission components DO NOT use solvents containing ac...

Page 72: ...s Service Manual Supplement includes ONLY the information that is new or updated for 2001 Model Year All other Service Manual information is in the 2000 Model Year Service Manual When you are using th...

Page 73: ...frequency transmitter The vehicle must be in PARK before the trunk lid can be unlatched with the transmitter The receiver may receive signals from up to four transmitters Each transmitter has its own...

Page 74: ...ipping and storage in the dealer lot Dealer lot storage mode pro vides limited VTSS and power door lock functions but disables the Remote Keyless Entry RKE func tions This mode is intended to be used...

Page 75: ...e door with the outside door handle DECKLID SOLENOID REMOVAL 1 Disconnect and isolate the battery negative cable Fig 1 2 Raise deck lid to the full up position 3 Unplug connector from solenoid 4 Remov...

Page 76: ...will unlock all doors Upon pressing the LOCK button the horn will sound a short CHIRP if enabled and flash the park lamps to notify that the all door lock signal was received and set Illuminated entr...

Page 77: ...odes Configuring a New Module Additionally all transmitters must be reprogrammed to the new RKE module INSTALLATION NOTE When replacing a faulty RKE Module the replacement module must be configured wi...

Page 78: ...a voltmeter check pin 7 for 12v If battery voltage is not present check wiring and or fuse for open Refer to Wiring Diagrams for a complete schematic of the mirror fold away system 5 Depress the mirro...

Page 79: ...per wire and connector repair procedures details of wire harness routing and retention connector pin out information and location views for the various wire harness connectors splices and grounds DIAG...

Page 80: ...pry up on window switch bezel and remove from door trim panel Fig 3 3 Disconnect wire connector from switch 4 Remove two switch retaining screws Fig 4 INSTALLATION 1 Install switch to trim bezel Inst...

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Page 82: ...ns which allows them to deploy with less force than prior airbags The primary passenger restraints in this vehicle are the seat belts which require active use by the vehicle occupants The front airbag...

Page 83: ...eplaced DIAGNOSIS AND TESTING SIDE IMPACT AIRBAG SYSTEM Refer to the proper Body Diagnostic Procedures manual STANDARD PROCEDURE MAINTENANCE INSPECTION Check the airbag warning lamp for proper opera t...

Page 84: ...f the system test are transmitted on the PCI bus circuit to the ACM once each second or on a change in lamp state ON OFF If the warning lamp status message from either SIACM contains a lamp ON request...

Page 85: ...tall the lower seat trim WARNING DO NOT CONNECT THE BATTERY NEG ATIVE CABLE REFER TO ELECTRICAL RESTRAINTS DIAGNOSIS AND TESTING AIRBAG SYSTEM FIRST 6 Close hood 7 Verify vehicle and system operation...

Page 86: ...B pillar Tighten seat belt anchor bolt to 40 N m 30 ft lbs torque 4 Install B pillar trim PASSENGER AIRBAG DESCRIPTION The passenger airbag Fig 9 is located behind the passenger airbag cover between t...

Page 87: ...airbag up until the wire connector is visible and disconnect the 4 way wire connector from the airbag Unlock the red locking tab and compress lock to release the connector Fig 11 DEPLOYED MODULE When...

Page 88: ...d module 4 Remove steering wheel Refer to Steering Col umn Steering Wheel Removal 5 Remove upper and lower steering column shrouds to gain access to clockspring wiring Refer to Steering Column Upper S...

Page 89: ...shrouds Be sure all wires are inside of shrouds 5 Install steering wheel ensuring the flats on hub align with the clock spring Pull the horn airbag and speed control leads through the larger slot Ens...

Page 90: ...and pull connector straight from module 8 Remove the seat airbag retaining nuts 9 Grasp the upper airbag side of the seat back trim cover and pull trim cover and cushion over top of seat back frame T...

Page 91: ...tioned 5 Position seat back trim cover and install seat back trim cover J straps on the upper lower and air bag side of seat back frame 6 Install the plastic back panel on the seat back Fig 15 Refer t...

Page 92: ...the lowest position when Installing adjuster knob 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...

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Page 94: ...ECURITY SYSTEM 8Wa 39 1 INSTRUMENT CLUSTER 8Wa 40 1 HORN CIGAR LIGHTER POWER OUTLET 8Wa 41 1 AIR CONDITIONING HEATER 8Wa 42 1 AIRBAG SYSTEM 8Wa 43 1 INTERIOR LIGHTING 8Wa 44 1 AUDIO SYSTEM 8Wa 47 1 RE...

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Page 96: ...eatures and characteris tics Diagrams are arranged such that the power B side of the circuit is placed near the top of the page and the ground B side of the circuit is placed near the bottom of the pa...

Page 97: ...Fig 1 WIRING DIAGRAM EXAMPLE 1 8Wa 01 2 8W 01 WIRING DIAGRAM INFORMATION PL WIRING DIAGRAM INFORMATION Continued ProCarManuals com 2001 NEON...

Page 98: ...Fig 2 WIRING DIAGRAM EXAMPLE 2 PL 8W 01 WIRING DIAGRAM INFORMATION 8Wa 01 3 WIRING DIAGRAM INFORMATION Continued ProCarManuals com 2001 NEON...

Page 99: ...Fig 3 WIRING DIAGRAM SYMBOLS 8Wa 01 4 8W 01 WIRING DIAGRAM INFORMATION PL WIRING DIAGRAM INFORMATION Continued ProCarManuals com 2001 NEON...

Page 100: ...CONVERTER AND MUFFLER WARNING DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY WARNING ALWAYS REMOVE RINGS WATCHES LOOSE HANGING JEWELRY AND LOOSE CLOT...

Page 101: ...are six steps which can aid in the procedure The steps are listed and explained below Always check for non factory items added to the vehicle before doing any diagnosis If the vehicle is equipped with...

Page 102: ...ARD PROCEDURE TESTING FOR SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1 Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits 2 Replace the blown fuse 3...

Page 103: ...minals Fig 8 4 Using special tool 6932 push the terminal to remove it from the connector Fig 9 5 Repair or replace the terminal as necessary PROBING TOOL PACKAGE 6807 TERMINAL PICK 6680 TERMINAL REMOV...

Page 104: ...ig 11 5 Pull on the wire to remove it from the connector 6 Repair or replace the terminal as necessary INSTALLATION 1 Reset the terminal locking tang 2 Insert the removed wire in the same cavity on th...

Page 105: ...remove the protective covering 3 Remove the diode from the harness pay atten tion to the current flow direction Fig 15 INSTALLATION 1 Remove the insulation from the wires in the harness Only remove en...

Page 106: ...epair wire to the proper length and remove one half 1 2 inch of insulation 3 Splice the repair wire to the wire harness 4 Insert the repaired wire into the connector 5 Install the connector locking we...

Page 107: ...ds of wire overlapping each other inside of the splice clip Fig 19 4 Using crimping tool Miller p n 8272 crimp the splice clip and wires together Fig 20 5 Solder the connection together using rosin co...

Page 108: ...EVAP Purge Solenoid 8Wa 30 Fog Lamp 8Wa 50 51 Fuel Injectors 8Wa 30 Fuel Pump Module 8Wa 30 Fuel Pump Relay 8Wa 30 Fuel Tank 8Wa 30 Component Page Fuses FB 8Wa 11 Fuses PDC 8Wa 11 Generator 8Wa 20 Gl...

Page 109: ...51 52 Throttle Position Sensor 8Wa 30 Torque Converter Clutch Solenoid 8Wa 30 Component Page Traction Control Switch 8Wa 35 Transmission Control Module 8Wa 31 Transmission Control Relay 8Wa 31 Transmi...

Page 110: ...4 Fuse 18 PDC 8Wa 10 7 13 Fuse 20 FB 8Wa 10 11 Fuse 20 PDC 8Wa 10 7 15 Fuse 21 PDC 8Wa 10 7 17 Fuse 22 PDC 8Wa 10 7 18 Fuse 23 PDC 8Wa 10 7 20 Fuse Block 8Wa 10 9 10 11 Generator 8Wa 10 19 Glove Box L...

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Page 132: ...ft Headlamp 8Wa 11 19 20 21 Component Page Left Lavalier Module 8Wa 11 15 20 Left License Lamp 8Wa 11 14 Left Park Turn Signal Lamp 8Wa 11 15 Left Side Impact 8Wa 11 12 Left Tail Stop Lamp 8Wa 11 14 L...

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Page 154: ...14 Left Side Impact 8Wa 15 9 Left Side Repeater Lamp 8Wa 15 5 Left Tail Stop Lamp 8Wa 15 14 Left Tail Stop Turn Signal Lamp 8Wa 15 13 License Lamp 8Wa 15 15 Low Note Horn 8Wa 15 5 7 Manifold Tuning V...

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Page 172: ...18 2 Instrument Cluster 8Wa 18 3 Left Side Impact 8Wa 18 3 Component Page Power Distribution Center 8Wa 18 2 Powertrain Control Module 8Wa 18 2 Radio 8Wa 18 3 Remote Keyless Entry Module 8Wa 18 3 Rig...

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Page 176: ...rter Motor 8Wa 20 2 Fuse 21 PDC 8Wa 20 2 Fusible Link 8Wa 20 2 G104 8Wa 20 2 Component Page G105 8Wa 20 2 Generator 8Wa 20 2 3 Inlet Air Temperature Sensor 8Wa 20 3 Power Distribution Center 8Wa 20 2...

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Page 180: ...elay 8Wa 21 2 Engine Starter Motor 8Wa 21 2 Fuse 9 PDC 8Wa 21 2 Fusible Link 8Wa 21 2 Component Page Generator 8Wa 21 2 Ignition Switch 8Wa 21 2 Power Distribution Center 8Wa 21 2 Powertrain Control M...

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Page 182: ...PDC 8Wa 30 32 Fuse Block 8Wa 30 9 10 24 25 32 G102 8Wa 30 4 13 14 17 18 19 27 29 30 31 33 Component Page G103 8Wa 30 13 27 29 G108 8Wa 30 2 G109 8Wa 30 2 G201 8Wa 30 12 28 G303 8Wa 30 10 25 Generator...

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Page 216: ...Up Lamp 8Wa 31 6 Component Page Output Speed Sensor 8Wa 31 4 Power Distribution Center 8Wa 31 3 7 8 Powertrain Control Module 8Wa 31 5 6 9 Right Back Up Lamp 8Wa 31 6 Throttle Position Sensor 8Wa 31...

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Page 226: ...8Wa 33 2 Fuse Block 8Wa 33 2 G102 8Wa 33 3 G103 8Wa 33 3 Component Page G201 8Wa 33 4 Instrument Cluster 8Wa 33 2 Left Speed Control Switch 8Wa 33 4 Powertrain Control Module 8Wa 33 2 3 4 Right Speed...

Page 227: ...ProCarManuals com 2001 NEON...

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Page 230: ...a 35 3 Fuse 23 PDC 8Wa 35 2 Fuse Block 8Wa 35 3 Component Page G102 8Wa 35 2 G204 8Wa 35 3 Instrument Cluster 8Wa 35 3 Left Front Wheel Speed Sensor 8Wa 35 4 Left Rear Wheel Speed Sensor 8Wa 35 4 Powe...

Page 231: ...ProCarManuals com 2001 NEON...

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Page 234: ...Component Page Left Lavalier Module 8Wa 39 10 Left Park Turn Signal Lamp 8Wa 39 10 Left Rear Door Lock Motor Ajar Switch 8Wa 39 4 5 9 Left Rear Turn Signal Lamp 8Wa 39 15 Left Side Repeater Lamp 8Wa...

Page 235: ...ProCarManuals com 2001 NEON...

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Page 250: ...10 14 15 16 17 18 19 Component Page Left Front Fog Lamp 8Wa 40 18 20 Left Front Side Marker Lamp 8Wa 40 5 Left Front Turn Signal Lamp 8Wa 40 5 Left Park Turn Signal Lamp 8Wa 40 5 Left Rear Door Lock M...

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Page 270: ...18 PDC 8Wa 41 2 3 G103 8Wa 41 2 3 G204 8Wa 41 4 High Note Horn 8Wa 41 2 Component Page Horn Relay 8Wa 41 2 3 Horn Switch 8Wa 41 2 3 Ignition Switch 8Wa 41 4 Low Note Horn 8Wa 41 2 3 Power Distribution...

Page 271: ...ProCarManuals com 2001 NEON...

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Page 274: ...42 3 4 Diode 8Wa 42 2 Fuse 6 FB 8Wa 42 3 4 6 Fuse 6 PDC 8Wa 42 5 Fuse 7 FB 8Wa 42 3 4 6 Fuse 10 FB 8Wa 42 2 5 Component Page Fuse 11 FB 8Wa 42 2 5 Fuse 15 FB 8Wa 42 3 4 Fuse 22 PDC 8Wa 42 2 Fuse Block...

Page 275: ...ProCarManuals com 2001 NEON...

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Page 280: ...FB 8Wa 43 3 Fuse 9 FB 8Wa 43 2 5 Fuse 10 FB 8Wa 43 3 Fuse 11 FB 8Wa 43 2 Component Page Fuse 12 FB 8Wa 43 3 5 Fuse Block 8Wa 43 2 3 5 G202 8Wa 43 2 3 5 Instrument Cluster 8Wa 43 2 3 Left Seat Airbag 8...

Page 281: ...ProCarManuals com 2001 NEON...

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Page 286: ...a 44 2 Glove Box Lamp Switch 8Wa 44 4 Component Page Headlamp Leveling Switch 8Wa 44 5 Instrument Cluster 8Wa 44 2 5 Left Visor Vanity Lamp 8Wa 44 4 Map Reading Lamp 8Wa 44 3 Multi Function Switch 8Wa...

Page 287: ...ProCarManuals com 2001 NEON...

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Page 292: ...a 47 2 Instrument Cluster 8Wa 47 2 Component Page Left Front Door Speaker 8Wa 47 4 Left Instrument Panel Speaker 8Wa 47 4 Left Rear Speaker 8Wa 47 5 Multi Function Switch 8Wa 47 2 Power Distribution C...

Page 293: ...ProCarManuals com 2001 NEON...

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Page 298: ...Fuse 10 PDC 8Wa 48 2 Fuse Block 8Wa 48 2 G201 8Wa 48 2 Component Page G301 8Wa 48 2 Instrument Cluster 8Wa 48 2 Power Distribution Center 8Wa 48 2 Rear Window Defogger Switch 8Wa 48 2 Rear Window Defo...

Page 299: ...ProCarManuals com 2001 NEON...

Page 300: ...ng Switch 8Wa 50 8 Component Page Instrument Cluster 8Wa 50 2 4 8 10 11 12 Left Front Fog Lamp 8Wa 50 11 13 Left Front Side Marker Lamp 8Wa 50 7 Left Headlamp 8Wa 50 3 5 Left Lavalier Module 8Wa 50 9...

Page 301: ...ProCarManuals com 2001 NEON...

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Page 314: ...Back Up Lamp 8Wa 51 2 Component Page Left License Lamp 8Wa 51 6 Left Rear Fog Lamp 8Wa 51 8 Left Tail Stop Lamp 8Wa 51 6 Left Tail Stop Turn Signal Lamp 8Wa 51 4 License Lamp 8Wa 51 4 Multi Function...

Page 315: ...ProCarManuals com 2001 NEON...

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Page 322: ...7 10 Component Page Left Front Turn Signal Lamp 8Wa 52 6 Left Park Turn Signal Lamp 8Wa 52 5 Left Rear Turn Signal Lamp 8Wa 52 10 Left Side Repeater Lamp 8Wa 52 7 Left Tail Stop Turn Signal Lamp 8Wa 5...

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Page 332: ...4 FB 8Wa 53 2 3 Fuse Block 8Wa 53 2 3 G103 8Wa 53 3 G201 8Wa 53 2 Component Page G204 8Wa 53 3 Windshield Washer Pump 8Wa 53 3 Wiper Motor 8Wa 53 3 Wiper Washer Switch 8Wa 53 2 3 PL 8W 53 WIPERS 8Wa...

Page 333: ...ProCarManuals com 2001 NEON...

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Page 336: ...FB 8Wa 60 3 4 6 Fuse 7 FB 8Wa 60 2 4 5 Fuse Block 8Wa 60 2 3 4 5 6 Component Page G203 8Wa 60 2 3 4 5 6 Passenger Door Lock Motor Ajar Switch 8Wa 60 4 Passenger Door Lock Switch 8Wa 60 4 Passenger Po...

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Page 342: ...8Wa 61 2 3 4 5 6 G201 8Wa 61 2 G203 8Wa 61 3 4 5 6 Component Page G204 8Wa 61 2 Left Rear Door Lock Motor Ajar Switch 8Wa 61 7 Passenger Cylinder Lock Switch 8Wa 61 5 6 Passenger Door Lock Motor Ajar...

Page 343: ...ProCarManuals com 2001 NEON...

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Page 350: ...3 Fuse 20 FB 8Wa 62 3 Fuse Block 8Wa 62 2 3 6 Component Page G203 8Wa 62 2 3 Passenger Door Lock Switch 8Wa 62 3 Passenger Power Mirror 8Wa 62 3 4 5 6 Power Distribution Center 8Wa 62 3 Power Mirror S...

Page 351: ...ProCarManuals com 2001 NEON...

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Page 356: ...POWER SEAT Component Page Fuse 13 FB 8Wa 63 2 Fuse Block 8Wa 63 2 G203 8Wa 63 2 Component Page Power Seat Motor 8Wa 63 2 Power Seat Switch 8Wa 63 2 PL 8W 63 POWER SEAT 8Wa 63 1 ProCarManuals com 2001...

Page 357: ...ProCarManuals com 2001 NEON...

Page 358: ...3 FB 8Wa 64 2 3 Fuse Block 8Wa 64 2 3 G204 8Wa 64 2 Sunroof Control Module 8Wa 64 2 3 Component Page Sunroof Motor 8Wa 64 3 Sunroof Switch 8Wa 64 2 3 Sunroof Vent Switch 8Wa 64 2 PL 8W 64 POWER SUNRO...

Page 359: ...ProCarManuals com 2001 NEON...

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Page 362: ...S207 8Wa 15 9 S208 8Wa 41 2 3 S209 8Wa 11 18 S210 8Wa 15 9 S211 8Wa 10 11 Component Page S212 8Wa 11 18 S213 8Wa 11 13 14 S214 8Wa 61 7 S215 8Wa 11 21 S216 8Wa 11 7 8 S217 8Wa 18 3 S218 8Wa 15 11 S219...

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Page 366: ...3 8Wa 80 21 C303 8Wa 80 21 C304 8Wa 80 21 C304 8Wa 80 22 C305 8Wa 80 22 C305 8Wa 80 23 C306 8Wa 80 23 C306 8Wa 80 23 Camshaft Position Sensor 8Wa 80 24 Cargo Lamp 8Wa 80 24 Center High Mounted Stop La...

Page 367: ...enoid RT 8Wa 80 41 Map Reading Lamps 8Wa 80 41 Component Page Multi Function Switch 8Wa 80 42 Output Speed Sensor EATX 8Wa 80 42 Oxygen Sensor 1 1 Upstream 8Wa 80 42 Oxygen Sensor 1 2 Downstream 8Wa 8...

Page 368: ...8Wa 80 57 Speed Control Servo 8Wa 80 58 Sunroof Control Module 8Wa 80 58 Component Page Sunroof Motor 8Wa 80 58 Sunroof Switch 8Wa 80 58 Sunroof Vent Switch 8Wa 80 59 Throttle Position Sensor 8Wa 80...

Page 369: ...H PRESSURE SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 C20 18BR OR LHD 1 6L A C SWITCH SENSE 1 C20 20BR OR A C SWITCH SENSE 2 C22 20DB WT PRESSURE SWITCH OUTPUT A C LOW PRESSURE SWITCH BLACK 2 WAY CAV C...

Page 370: ...1 SIGNAL 5 F859 20DG PK PEDAL POSITION SENSOR N0 2 5V SUPPLY 6 7 8 K981 20BR DG PEDAL POSITION SENSOR NO 2 GROUND 9 10 K81 20DB DG PEDAL POSITION SENSOR NO 2 SIGNAL AIRBAG CONTROL MODULE YELLOW 23 WA...

Page 371: ...LEVEL SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION B Z1 18BK GROUND A G15 18GY RD 2 0L BRAKE FLUID LEVEL SWITCH SENSE A G9 20GY BK 1 6L RED BRAKE WARNING INDICATOR DRIVER BRAKE LAMP SWITCH 6 WAY CAV CIRCU...

Page 372: ...V CIRCUIT 1 A142 18DG OR 2 K4 20BK LB 3 K6 18VT WT 4 K7 20OR 5 K22 20OR DB 6 K90 20TN 7 K119 20LG BK MTX 8 K127 18BK OR 9 10 K24 18GY BK EATX 11 12 13 14 C101 2 0L BLACK ENGINE SIDE CAV CIRCUIT 1 A142...

Page 373: ...T 1 V37 20RD LG 2 G9 20GY BK 3 K29 20WT PK 4 K10 20WT 5 K52 20PK BK 6 K119 20LG BK 7 T141 20YL RD 8 C27 18DB PK 9 C28 18DB OR 10 K51 18DB YL 11 K31 18BR 12 D25 20VT YL 13 D20 20LG 14 D21 20PK C102 2 0...

Page 374: ...4 T40 14BR 5 A142 18DG OR 6 K90 20TN 7 K921 20BR LG 8 K199 18BR VT RHD 8 K199 20BR LG LHD 9 K127 20DB OR LHD 9 K127 18BK OR RHD 10 K141 20TN WT 11 L50 20WT TN 12 A14 18RD WT 13 K106 18WT DG 14 K107 1...

Page 375: ...16RD OR 23 A41 14YL 23 A41 14YL EATX 24 A1 14RD 24 A1 14RD 25 L43 14VT C103 BLACK HD LP DASH SIDE CAV CIRCUIT B14 B2 G70 20BR TN RKE B3 L160 18TN RD B4 L60 20TN BUILT UP EXPORT B5 M1 20PK B6 A15 20WT...

Page 376: ...D25 20VT YL 21 22 A2 12PK BK 23 A3 12RD WT 24 A4 10BK RD 25 C104 BLACK I P SIDE CAV CIRCUIT C13 L50 20WT TN C1 L39 20LB EXCEPT BUILT UP EXPORT C2 C3 C21 22DB OR C4 L61 20LG BUILT UP EXPORT C5 L161 18...

Page 377: ...2 A141 18DG WT 3 K106 18WT DG EXCEPT BUILT UP EXPORT 4 K107 18YL EXCEPT BUILT UP EX PORT 5 6 L1 18VT BK 7 L7 20BK YL 7 L7 20BK YL 8 9 10 M1 20PK C106 BLACK ABS SENSOR SIDE CAV CIRCUIT 1 B1 20YL DB 2 B...

Page 378: ...5 T41 18BR YL ATX 6 C109 BLACK HD LP DASH SIDE CAV CIRCUIT 1 L39 16LB RHD 1 L39 18LB LHD EXCEPT BUILT UP EXPORT 2 X2 18DG RD DUAL HORNS CHRYSLER 3 Z1 18BK C109 BLACK FOG LAMP JUMPER SIDE CAV CIRCUIT 1...

Page 379: ...3 18OR BK POWER MIRRORS WINDOWS 7 P36 18PK VT POWER MIRRORS WINDOWS 7 P36 18PK VT POWER MIRRORS WINDOWS 8 M9 20LB OR 9 P96 20LG BK POWER MIRRORS WINDOWS 10 P93 20YL WT LHD POWER MIRRORS WINDOWS 10 P94...

Page 380: ...R RORS WINDOWS 11 F20 20WT POWER MIRRORS WIN DOWS POWER LOCKS 12 P91 20WT BK RHD POWER MIR RORS WINDOWS 12 P95 20DB WT LHD POWER MIR RORS WINDOWS 13 X53 20DG BASE 13 P92 20YL POWER MIRRORS WIN DOWS 14...

Page 381: ...OF WIRING SIDE CAV CIRCUIT 1 C2 22DB YL 2 F20 20WT 3 C21 22DB OR 4 C1 14DG 5 6 C7 14BK TN C203 LT GRAY I P SIDE CAV CIRCUIT 1 C2 22DB YL A C 2 F20 22WT A C 3 C21 22DB OR A C 4 C1 14DG 5 6 C7 14BK TN C...

Page 382: ...LOCKS 10 P93 20YL WT LHD POWER MIR RORS WINDOWS 10 P94 20WT YL RHD POWER MIR RORS WINDOWS 11 F20 20WT POWER MIRRORS WIN DOWS POWER LOCKS 12 P91 20WT BK RHD POWER MIR RORS WINDOWS 12 P95 20DB WT LHD P...

Page 383: ...IR RORS WINDOWS 11 F20 20WT POWER MIRRORS WIN DOWS POWER LOCKS 12 P91 20WT BK RHD 12 P95 20DB WT LHD POWER MIR RORS WINDOWS 13 P92 20YL POWER MIRRORS WIN DOWS 13 X53 20DG BASE 14 15 X53 20DG LHD POWER...

Page 384: ...YELLOW SIDE AIRBAG JUMPER SIDE CAV CIRCUIT 1 2 3 R32 18YL OR 4 R34 18OR YL C208 YELLOW 4 WAY SEAT SIDE CAV CIRCUIT 1 2 3 R32 18OR 4 R34 18WT C209 YELLOW SIDE AIRBAG JUMPER SIDE CAV CIRCUIT 1 2 3 R31 1...

Page 385: ...EXPORT 5 6 Z1 18BK BUILT UP EXPORT C301 RED UNIBODY SIDE CAV CIRCUIT 1 M1 20PK 2 3 M2 18YL 4 G120 18WT DB BUILT UP EXPORT 5 6 Z1 18BK BUILT UP EXPORT C302 BLACK DECKLID SIDE CAV CIRCUIT 1 L50 20WT TN...

Page 386: ...1 2 M9 20LB OR 3 P33 18OR BK POWER LOCKS 4 5 P36 18PK VT POWER LOCKS 6 Z1 18BK 7 C303 BLACK REAR DOOR SIDE CAV CIRCUIT 1 2 M9 18LB OR 3 P33 18OR BK POWER LOCKS 4 5 P36 18PK VT POWER LOCKS 6 Z1 20BK 7...

Page 387: ...20LG RD 4 L7 20BK YL 5 L62 18BR RD 6 L63 18DG RD 7 X51 18BR YL 8 X52 18DB WT 9 L50 20WT TN 10 X5 20WT RD BUILT UP EXPORT 11 G120 18WT DB BUILT UP EXPORT 12 G4 18DB 13 M2 18YL 14 M9 20LB OR 15 X57 18B...

Page 388: ...L38 16BR WT BUILT UP EXPORT A13 M2 18YL A25 A15 X57 20BR LB A16 X58 20DB OR A17 F12 18DB WT EXCEPT BUILT UP EX PORT A18 A19 P33 18OR BK RKE A20 A21 Q2 16LG BK RKE A22 A23 P36 18PK VT RKE A24 C15 12BK...

Page 389: ...CARGO LAMP BLACK 2 WAY CAV CIRCUIT FUNCTION 1 M1 20PK FUSED B 2 G78 22TN BK DECKLID AJAR SWITCH SENSE CENTER HIGH MOUNTED STOP LAMP BLACK 2 WAY CAV CIRCUIT FUNCTION 1 L50 20WT TN BRAKE LAMP SWITCH OUT...

Page 390: ...GER BLACK 8 WAY CAV CIRCUIT FUNCTION 1 24GY WT AUDIO OUT RIGHT 2 24OR TN PANEL LAMPS DIMMER SIGNAL 3 24VT YL PCI BUS 4 24RD IGNITION SWITCH OUTPUT 5 24DG WT AUDIO OUT LEFT 6 24BK OR GROUND 7 22BK TN G...

Page 391: ...CIRCUIT FUNCTION 1 K924 20BR WT 1 6L CRANKSHAFT POSITION SENSOR GROUND 1 K7 20OR 2 0L 8V SUPPLY 2 K24 20GY BK 1 6L CRANKSHAFT POSITION SENSOR SIGNAL 2 K4 20BK LB 2 0L SENSOR GROUND 3 K7 20OR 1 6L 8V...

Page 392: ...CTION 1 Q2 14LG BK DECKLID RELEASE RELAY OUTPUT 2 Z1 14BK GROUND DECKLID SECURITY SWITCH KNOCK OUT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 G71 20VT YL DECKLID SECURITY SWITCH SENSE DOME LAM...

Page 393: ...AIRBAG LINE 1 2 R45 18DG LB DRIVER AIRBAG LINE 2 DRIVER CYLINDER LOCK SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 P96 18LG RHD RIGHT DOOR LOCK SWITCH MUX 1 P97 18LG LHD LEFT DOOR LOCK SWITCH MUX 2 Z14 1...

Page 394: ...HD LEFT DOOR SWITCH MUX 3 Z14 18BK GROUND 3 Z14 18BK YL GROUND DRIVER POWER MIRROR LHD GRAY 7 WAY CAV CIRCUIT FUNCTION 1 C16 20LB YL FUSED REAR WINDOW DEFOGGER SWITCH OUTPUT 2 P94 20WT YL MIRROR HORIZ...

Page 395: ...UNCTION 1 2 Z8 14BK VT GROUND 3 Z8 14BK VT GROUND 4 F21 14TN FUSED IGNITION SWITCH OUTPUT RUN 5 Q16 14BR WT LHD MASTER WINDOW SWITCH RIGHT FRONT UP 5 Q26 14VT WT RHD MASTER WINDOW SWITCH RIGHT FRONT D...

Page 396: ...PRESSURE SWITCH GREEN 2 WAY CAV CIRCUIT FUNCTION 1 G6 20GY ENGINE OIL PRESSURE SWITCH SENSE 2 PROPORTIONAL EVAP PURGE SOLENOID BLACK 2 WAY CAV CIRCUIT FUNCTION 1 F12 18DB WT 1 6L FUSED IGNITION SWITCH...

Page 397: ...K14 18LB BR FUEL INJECTOR NO 4 DRIVER 2 A142 18DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL PUMP MODULE LT GRAY 4 WAY CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 Z2 18BK LG GROUND 3 G4 18DB FUEL LEVEL SENS...

Page 398: ...2 WAY CAV CIRCUIT FUNCTION 1 G70 18BR TN HOOD AJAR SWITCH SENSE 2 Z1 18BK GROUND IDLE AIR CONTROL MOTOR 2 0L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K60 20YL BK IDLE AIR CONTROL DRIVER 2 K39 20GY RD EATX...

Page 399: ...R TEMPERATURE SENSOR SIGNAL 2 K921 20BR LG 1 6L INLET AIR TEMPERATURE SENSOR GROUND 2 K4 20BK LB 2 0L SENSOR GROUND INPUT SPEED SENSOR EATX GRAY 2 WAY CAV CIRCUIT FUNCTION 1 T13 18DB BK SPEED SENSOR G...

Page 400: ...RNING INDICATOR DRIVER 23 G26 22LB KEY IN IGNITION SWITCH SENSE 24 G74 18TN RHD RIGHT FRONT DOOR AJAR SWITCH SENSE 24 G75 18TN LHD LEFT FRONT DOOR AJAR SWITCH SENSE 25 G10 20LG RD SEAT BELT SWITCH SEN...

Page 401: ...Y CAV CIRCUIT FUNCTION B Z1 20BK GROUND A L39 16LB FUSED FOG LAMP SWITCH OUTPUT LEFT FRONT FOG LAMP EXCEPT BUILT UP EXPORT BLACK 2 WAY CAV CIRCUIT FUNCTION B Z1 18BK GROUND A L39 18LB FUSED FOG LAMP S...

Page 402: ...ADLAMP BUILT UP EXPORT 3 WAY CAV CIRCUIT FUNCTION 1 L3 16RD OR DIMMER SWITCH HIGH BEAM OUTPUT 2 L43 14VT FUSED LEFT LOW BEAM OUTPUT 3 Z1 14BK GROUND LEFT HEADLAMP EXCEPT BUILT UP EXPORT BLACK 3 WAY CA...

Page 403: ...SIGNAL LAMP EXCEPT BUILT UP EXPORT BLACK 3 WAY CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 L7 18BK YL HEADLAMP SWITCH OUTPUT 3 L161 18LG OR LEFT TURN SIGNAL LEFT REAR DOOR AJAR SWITCH 2 WAY CAV CIRCUIT FU...

Page 404: ...FT REAR TURN SIGNAL LAMP BUILT UP EXPORT GRAY 3 WAY CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 3 L63 18DG RD LEFT TURN SIGNAL LEFT REAR WHEEL SPEED SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 B4 20LG 12 VO...

Page 405: ...RT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 L61 20LG LEFT TURN SIGNAL 2 Z1 20BK GROUND LEFT TAIL STOP LAMP BUILT UP EXPORT BLACK 3 WAY CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 L7 18BK YL HEADLAMP SWITCH OUTP...

Page 406: ...UIT FUNCTION 1 K1 20DG RD MAP SENSOR SIGNAL 2 K901 20DB VT 1 6L MAP SENSOR GROUND 2 K4 18BK LB 2 0L SENSOR GROUND 3 K6 18VT WT 5V SUPPLY MANIFOLD TUNING VALVE SOLENOID RT BLACK 2 WAY CAV CIRCUIT FUNCT...

Page 407: ...UP EX PORT DIMMER SWITCH LOW BEAM OUTPUT 13 F61 16WT OR BUILT UP EXPORT FUSED B 14 L39 16LB BUILT IP EXPORT FRONT FOG LAMP SWITCH OUTPUT 14 L39 16LB BUILT UP EXPORT FRONT FOG LAMP SWITCH OUTPUT 14 F39...

Page 408: ...2 T41 18BR YL PARK NEUTRAL POSITION SWITCH SENSE 3 F20 18WT FUSED IGNITION SWITCH OUTPUT RUN PASSENGER AIRBAG YELLOW 4 WAY CAV CIRCUIT FUNCTION 1 2 3 R44 18DG YL PASSENGER AIRBAG LINE 2 4 R42 18BK YL...

Page 409: ...GHT DOOR LOCK SWITCH MUX 2 P96 18LG LHD RIGHT DOOR LOCK SWITCH MUX 3 Z14 18BK GROUND 3 Z14 18BK YL GROUND PASSENGER POWER MIRROR LHD GRAY 7 WAY CAV CIRCUIT FUNCTION 1 C16 20LB YL HEATED MIRROR 2 P93 2...

Page 410: ...OWER MIRROR SWITCH LHD GRAY 10 WAY CAV CIRCUIT FUNCTION 1 P95 20DB WT MIRROR VERTICAL 2 P93 20YL WT MIRROR HORIZONTAL 3 F20 20WT FUSED IGNITION SWITCH OUTPUT RUN 4 Z8 20BK VT GROUND 5 6 P91 20WT BK MI...

Page 411: ...C1 2 0L BLACK 40 WAY CAV CIRCUIT FUNCTION 1 2 3 K17 18DB TN IGNITION COIL NO 2 DRIVER 4 5 V32 20YL RD SPEED CONTROL SUPPLY 6 A142 18DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT 7 K13 18YL WT FUEL INJECTOR N...

Page 412: ...K4 20BK LB SENSOR GROUND 44 K7 20OR 8V SUPPLY 45 K10 20WT STEERING PRESSURE SWITCH SENSE 46 A14 18RD WT FUSED B 47 Z11 18BK WT GROUND 48 49 K60 20YL BK IDLE AIR CONTROL DRIVER 50 Z12 18BK TN GROUND 51...

Page 413: ...TURE SENSOR GROUND 10 N907 20BR OR VEHICLE SPEED SENSOR GROUND 11 K901 20DB VT MAP SENSOR GROUND 12 F858 20PK PEDAL POSITION SENSOR NO 1 5V SUPPLY 13 F859 20DG PK PEDAL POSITION SENSOR NO 2 5V SUPPLY...

Page 414: ...N SWITCH OUTPUT RUN START 62 63 64 65 C27 18DB PK RADIATOR FAN RELAY CONTROL 66 K31 18BR FUEL PUMP RELAY CONTROL 67 K106 18WT DG LEAK DETECTION PUMP SOLENOID CONTROL 68 L50 20WT TN BRAKE LAMP SWITCH O...

Page 415: ...52 20DB WT RIGHT REAR SPEAKER 4 X53 20DG LEFT FRONT SPEAKER 5 X54 20VT RIGHT FRONT SPEAKER 6 X57 20BR LB LEFT REAR SPEAKER 7 X58 20DB OR RIGHT REAR SPEAKER RADIO C2 GRAY 7 WAY CAV CIRCUIT FUNCTION 1 2...

Page 416: ...3 F35 16RD FUSED B 4 P33 18OR BK DOOR LOCK RELAY OUTPUT 5 P34 18PK BK DRIVER DOOR UNLOCK RELAY OUTPUT 6 P36 18PK VT DOOR UNLOCK RELAY OUTPUT 7 M9 20LB OR RHD PASSENGER DOOR AJAR RKE SENSE 7 M9 20DB OR...

Page 417: ...GHT BACK UP LAMP BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 L1 18VT BK BACK UP LAMP FEED RIGHT FRONT DOOR SPEAKER BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X54 20VT RIGHT FRONT SPEAKER 2 X56 20DB RD...

Page 418: ...GROUND RIGHT FRONT WHEEL SPEED SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 B7 18WT 12 VOLT SUPPLY 2 B6 18WT DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL RIGHT HEADLAMP BUILT UP EXPORT 3 WAY CAV CIRCUIT FUN...

Page 419: ...D FUSED RIGHT LOW BEAM OUTPUT RIGHT LICENSE LAMP BUILT UP EXPORT NATURAL 2 WAY CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 L7 18BK YL HEADLAMP SWITCH OUTPUT RIGHT PARK TURN SIGNAL LAMP EXCEPT BUILT UP EXP...

Page 420: ...FOG LAMP BUILT UP EXPORT GRAY 3 WAY CAV CIRCUIT FUNCTION 1 Z1 16BK GROUND 2 3 L38 16BR WT REAR FOG LAMP FEED RIGHT REAR SPEAKER BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X58 18DB OR RIGHT REAR SPEAKER 2 X52...

Page 421: ...F15 18DG WT FUSED IGNITION SWITCH OUTPUT RUN START 2 3 R34 18OR YL RIGHT SEAT SQUIB LINE 1 4 R32 18YL OR RIGHT SEAT SQUIB LINE 2 5 Z6 18BK PK GROUND 6 7 8 D25 18VT YL PCI BUS RIGHT SIDE REPEATER LAMP...

Page 422: ...K 2 WAY CAV CIRCUIT FUNCTION 1 G10 20LG RD SEAT BELT SWITCH SENSE 2 Z1 18BK GROUND SENTRY KEY IMMOBILIZER MODULE BLACK 6 WAY CAV CIRCUIT FUNCTION 1 2 D25 22VT YL PCI BUS 3 4 G5 20DB WT FUSED IGNITION...

Page 423: ...0OR SUNROOF VENT SWITCH G Q43 18WT RD SUNROOF VENT F Z3 18BK VT GROUND E F10 18YL RD FUSED IGNITION SWITCH OUTPUT RUN ACC D C Z3 18BK OR GROUND B Q5 18WT SUNROOF MOTOR B A Q6 18DB SUNROOF MOTOR B SUNR...

Page 424: ...SIGNAL 3 K6 18VT WT 5V SUPPLY TORQUE CONVERTER CLUTCH SOLENOID ATX BLACK 3 WAY CAV CIRCUIT FUNCTION 1 2 K54 18OR BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL 3 F12 18DB WT FUSED IGNITION SWITCH OUTPUT...

Page 425: ...OUTPUT SPEED SENSOR SIGNAL 15 T15 18LG TRANSMISSION RELAY CONTROL 16 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT 17 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT 18 19 T19 18WT 2 4 SOLENOID CONTROL 20 T2...

Page 426: ...RCUIT FUNCTION 1 F20 20WT FUSED IGNITION SWITCH OUTPUT RUN 2 3 T13 18BD BK SPEED SENSOR GROUND 4 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL 5 T41 18BR YL PARK NEUTRAL POSITION SWITCH SENSE T41 6...

Page 427: ...PUT WIPER WASHER SWITCH GRAY 7 WAY CAV CIRCUIT FUNCTION 1 V5 16DG YL WIPER PARK SWITCH SENSE 2 Z2 22BK LG GROUND 3 V10 18BR WASHER PUMP CONTROL SWITCH OUTPUT 4 V6 16DB FUSED IGNITION SWITCH OUTPUT RUN...

Page 428: ...K Right Rear of Engine Compartment 1 3 Accelerator Pedal Position Sensor 1 6L BK Left Front Kick Panel N S Airbag Control Module YL Center Console Behind Shift Lever 11 Antenna BK Center of Instrument...

Page 429: ...nel 8 Clockspring GR Rear of Steering Wheel 7 Clutch Interlock Upstop Switch MTX BK Top of Clutch Pedal 2 Controller Antilock Brake BK Near Left Strut Tower 2 7 Crankshaft Position Sensor BK Right Fro...

Page 430: ...Panel 8 9 G203 Lower Center of Instrument Panel 8 9 G204 Lower Center of Instrument Panel 8 9 G301 Inner Left Rear Quarter Panel 13 G302 Inner Right Rear Quarter Panel 14 G303 Inner Left Rear Quarter...

Page 431: ...13 Left Rear Turn Signal Lamp Built Up Export GY Left Rear Facia 13 Left Rear Wheel Speed Sensor BL At Left Rear Wheel Opening N S Left Seat Airbag Left Side of Seat N S Left Side Impact Airbag Contro...

Page 432: ...der Side Shield 4 Powertrain Control Module C2 BK Left Fender Side Shield 2 PVC Heater 2 0L BK Left Rear Engine Compartment N S Radiator Fan Motor BK Front of Engine Compartment 1 2 Radio C1 BK Rear o...

Page 433: ...ter Lower Instrument Panel 7 Siren Built Up Export Behind Right Rear Fender N S Speed Control Servo BK Right Rear of Engine Compartment 1 3 Sunroof Control Module Center Roof Support Bracket N S Sunro...

Page 434: ...Fig 1 FRONT LIGHTING CONNECTIONS LHD PL 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 7 CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 435: ...Fig 2 LEFT HEADLAMP CONNECTIONS LHD 8Wa 90 8 8W 90 CONNECTOR GROUND LOCATIONS PL CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 436: ...Fig 3 ENGINE COMPARTMENT CONNECTIONS RIGHT SIDE LHD PL 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 9 CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 437: ...Fig 4 ENGINE CONNECTIONS RIGHT FRONT LHD Fig 5 ENGINE CONNECTIONS LEFT REAR LHD 8Wa 90 10 8W 90 CONNECTOR GROUND LOCATIONS PL CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 438: ...Fig 6 ENGINE COMPARTMENT CONNECTIONS LEFT SIDE LHD PL 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 11 CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 439: ...Fig 7 INSTRUMENT PANEL CONNECTIONS LHD 8Wa 90 12 8W 90 CONNECTOR GROUND LOCATIONS PL CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 440: ...Fig 8 INSTRUMENT PANEL CONNECTIONS RIGHT SIDE LHD PL 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 13 CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 441: ...Fig 9 INSTRUMENT PANEL CONNECTIONS LHD 8Wa 90 14 8W 90 CONNECTOR GROUND LOCATIONS PL CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 442: ...Fig 10 ROOF CONNECTIONS LHD Fig 11 CENTER CONSOLE CONNECTIONS LHD PL 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 15 CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 443: ...Fig 12 BODY CONNECTIONS LHD 8Wa 90 16 8W 90 CONNECTOR GROUND LOCATIONS PL CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 444: ...Fig 13 BODY CONNECTIONS LHD PL 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 17 CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 445: ...Fig 14 BODY CONNECTIONS RIGHT REAR LHD 8Wa 90 18 8W 90 CONNECTOR GROUND LOCATIONS PL CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 446: ...Fig 15 BODY CONNECTIONS RIGHT REAR LHD PL 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 19 CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 447: ...Fig 16 DOOR CONNECTIONS DRIVER LHD Fig 17 DOOR CONNECTIONS PASSENGER LHD 8Wa 90 20 8W 90 CONNECTOR GROUND LOCATIONS PL CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 448: ...Fig 18 DOOR CONNECTIONS REAR LHD Fig 19 DECKLID CONNECTIONS LHD PL 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 21 CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 449: ...esistor Block BK In Plenum 25 Brake Fluid Level Switch BK Near Right Front Strut Tower 20 21 Brake Lamp Switch Top of Brake Pedal 25 Brake Transmission Shift Interlock Solenoid WT Right Side of Instru...

Page 450: ...ing Wheel N S Driver Cylinder Lock Switch BK At Driver Door 37 Driver Door Ajar Switch Right B Pillar 34 Driver Door Lock Motor Ajar Switch BK At Driver Door 37 Driver Door Lock Switch BK At Driver Do...

Page 451: ...ature Sensor BK Left Front of Engine Compartment 26 Input Speed Sensor EATX GY Lower Left of Engine Compartment N S Instrument Cluster BK Right Upper Instrument Panel 28 Knock Sensor 1 6L BK Left Fron...

Page 452: ...ssion N S Passenger Airbag YL Left Side of Instrument Panel 28 Passenger Cylinder Lock Switch BK At Passenger Door 36 Passenger Door Ajar Switch Left B Pillar N S Passenger Door Lock Motor Ajar Switch...

Page 453: ...34 Right Rear Wheel Speed Sensor BK At Right Rear Wheel Opening N S Right Seat Airbag Right Side of Seat N S Right Side Impact Airbag Control Module Base of Right 9B9 Pillar 32 Right Side Repeater La...

Page 454: ...BK At Lamp N S Vehicle Speed Sensor BK Right Front Wheel Opening 24 Windshield Washer Pump RD Left Rear Engine Compartment 20 Wiper Washer Switch GY Lower Center of Instrument Panel 28 Wiper Motor BK...

Page 455: ...Fig 20 ENGINE COMPARTMENT CONNECTIONS FRONT RHD 8Wa 90 28 8W 90 CONNECTOR GROUND LOCATIONS PL CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 456: ...Fig 21 ENGINE COMPARTMENT CONNECTIONS LEFT SIDE RHD PL 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 29 CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 457: ...Fig 22 ENGINE COMPARTMENT CONNECTIONS RIGHT SIDE RHD 8Wa 90 30 8W 90 CONNECTOR GROUND LOCATIONS PL CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 458: ...Fig 23 ENGINE CONNECTIONS RIGHT FRONT RHD Fig 24 ENGINE CONNECTIONS LEFT REAR RHD PL 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 31 CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 459: ...Fig 25 DASH PANEL PLENUM CONNECTIONS RHD 8Wa 90 32 8W 90 CONNECTOR GROUND LOCATIONS PL CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 460: ...Fig 26 LEFT SIDE ENGINE COMPARTMENT RHD PL 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 33 CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 461: ...Fig 27 INSTRUMENT PANEL CONNECTIONS RHD 8Wa 90 34 8W 90 CONNECTOR GROUND LOCATIONS PL CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 462: ...Fig 28 INSTRUMENT PANEL CONNECTIONS RHD PL 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 35 CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 463: ...Fig 29 INSTRUMENT PANEL CONNECTIONS RHD 8Wa 90 36 8W 90 CONNECTOR GROUND LOCATIONS PL CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 464: ...Fig 30 ROOF CONNECTIONS RHD Fig 31 CENTER CONSOLE RHD PL 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 37 CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 465: ...Fig 32 BODY CONNECTIONS RHD 8Wa 90 38 8W 90 CONNECTOR GROUND LOCATIONS PL CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 466: ...Fig 33 BODY CONNECTIONS RHD PL 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 39 CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 467: ...Fig 34 BODY CONNECTIONS RHD 8Wa 90 40 8W 90 CONNECTOR GROUND LOCATIONS PL CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 468: ...Fig 35 BODY CONNECTIONS RHD PL 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 41 CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 469: ...Fig 36 DOOR CONNECTIONS PASSENGER RHD Fig 37 DOOR CONNECTIONS DRIVER RHD 8Wa 90 42 8W 90 CONNECTOR GROUND LOCATIONS PL CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 470: ...Fig 38 DOOR CONNECTIONS REAR RHD Fig 39 DECKLID CONNECTIONS RHD PL 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 43 CONNECTOR GROUND LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 471: ...ProCarManuals com 2001 NEON...

Page 472: ...09 Near Power Distribution Center 2 S110 Near Left Front Side Marker Lamp 1 S111 Near Right Headlamp 3 S112 Near Power Distribution Center 2 S113 Near Throttle Position Sensor T O 2 S114 Near Throttle...

Page 473: ...aker T O 7 S202 Near Right Instrument Panel Speaker T O 7 S203 Near Inline C202 T O 7 S204 Near Inline C202 T O 7 S205 Near Passenger Airbag T O 7 S206 Near A C Heater Control T O 6 S207 Near A C Heat...

Page 474: ...Driver Power Mirror T O 15 S251 Near Inline C204 9 S252 Near Left Visor Vanity Mirror Lamp T O 9 S301 Near Fuel Pump Module T O N S S302 Near Seat Belt Switch T O 11 13 S303 Near Seat Belt Switch T O...

Page 475: ...Fig 1 ENGINE COMPARTMENT SPLICES FRONT LHD 8Wa 95 4 8W 95 SPLICE LOCATIONS PL SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 476: ...Fig 2 ENGINE COMPARTMENT SPLICES RIGHT SIDE LHD PL 8W 95 SPLICE LOCATIONS 8Wa 95 5 SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 477: ...Fig 3 ENGINE COMPARTMENT SPLICES RIGHT SIDE LHD 8Wa 95 6 8W 95 SPLICE LOCATIONS PL SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 478: ...Fig 4 ENGINE SPLICES FRONT LEFT LHD PL 8W 95 SPLICE LOCATIONS 8Wa 95 7 SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 479: ...Fig 5 ENGINE SPLICES RIGHT REAR LHD 8Wa 95 8 8W 95 SPLICE LOCATIONS PL SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 480: ...Fig 6 INSTRUMENT PANEL SPLICES CENTER LHD PL 8W 95 SPLICE LOCATIONS 8Wa 95 9 SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 481: ...Fig 7 INSTRUMENT PANEL SPLICES BOTTOM REAR LHD 8Wa 95 10 8W 95 SPLICE LOCATIONS PL SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 482: ...Fig 8 INSTRUMENT PANEL SPLICES TOP REAR LHD Fig 9 ROOF SPLICES LHD PL 8W 95 SPLICE LOCATIONS 8Wa 95 11 SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 483: ...Fig 10 CENTER CONSOLE SPLICES LHD 8Wa 95 12 8W 95 SPLICE LOCATIONS PL SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 484: ...Fig 11 BODY SPLICES LHD PL 8W 95 SPLICE LOCATIONS 8Wa 95 13 SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 485: ...Fig 12 BODY SPLICES LHD 8Wa 95 14 8W 95 SPLICE LOCATIONS PL SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 486: ...Fig 13 LEFT BODY SPLICES LHD PL 8W 95 SPLICE LOCATIONS 8Wa 95 15 SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 487: ...Fig 14 RIGHT BODY SPLICES LHD 8Wa 95 16 8W 95 SPLICE LOCATIONS PL SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 488: ...Fig 15 DOOR SPLICES LHD Fig 16 DECKLID SPLICES LHD PL 8W 95 SPLICE LOCATIONS 8Wa 95 17 SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 489: ...Right Front Park Turn Signal Lamp 18 S117 Near A C Compressor Clutch T O 19 S118 Near Left Repeater Lamp 17 18 S119 Near Radiator Fan Motor T O 17 S120 Near Siren T O 17 S121 1 6L Near Ground Point G1...

Page 490: ...ear Inline C205 T O N S S212 Near Instrument Cluster T O 23 S213 Near Instrument Cluster T O N S S214 Near Instrument Cluster T O 23 S215 Near Fuse Block T O 23 S216 Near Instrument Cluster T O 23 S21...

Page 491: ...ar Fuel Pump Module T O 26 S304 Near Fuel Pump Module T O 26 S305 Near Driver Door Ajar Switch T O 26 S306 Near Fuel Pump Module T O 26 S307 Near Fuel Pump Module T O 26 S308 Near Left Rear Door Ajar...

Page 492: ...Fig 17 ENGINE COMPARTMENT SPLICES FRONT RHD PL 8W 95 SPLICE LOCATIONS 8Wa 95 21 SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 493: ...Fig 18 ENGINE COMPARTMENT SPLICES RIGHT SIDE RHD 8Wa 95 22 8W 95 SPLICE LOCATIONS PL SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 494: ...Fig 19 ENGINE COMPARTMENT SPLICES LEFT SIDE RHD PL 8W 95 SPLICE LOCATIONS 8Wa 95 23 SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 495: ...Fig 20 DASH PANEL SPLICES RHD 8Wa 95 24 8W 95 SPLICE LOCATIONS PL SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 496: ...Fig 21 ENGINE SPLICES FRONT LEFT RHD PL 8W 95 SPLICE LOCATIONS 8Wa 95 25 SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 497: ...Fig 22 ENGINE SPLICES REAR RIGHT RHD 8Wa 95 26 8W 95 SPLICE LOCATIONS PL SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 498: ...Fig 23 INSTRUMENT PANEL SPLICES RHD PL 8W 95 SPLICE LOCATIONS 8Wa 95 27 SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 499: ...Fig 24 ROOF SPLICES RHD Fig 25 CENTER CONSOLE SPLICES RHD 8Wa 95 28 8W 95 SPLICE LOCATIONS PL SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 500: ...Fig 26 LEFT BODY SPLICES RHD PL 8W 95 SPLICE LOCATIONS 8Wa 95 29 SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 501: ...Fig 27 RIGHT BODY SPLICES RHD 8Wa 95 30 8W 95 SPLICE LOCATIONS PL SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 502: ...Fig 28 DOOR SPLICES RHD Fig 29 DECKLID SPLICES RHD PL 8W 95 SPLICE LOCATIONS 8Wa 95 31 SPLICE LOCATIONS Continued ProCarManuals com 2001 NEON...

Page 503: ...ProCarManuals com 2001 NEON...

Page 504: ...switch is located on the right rear side of the engine block Fig 1 The oil pressure switch is a pressure sensitive switch that is activated by the engine s oil pressure in the main oil gallery The swi...

Page 505: ...onnect negative cable from battery 2 Perform fuel system pressure release procedure before attempting any repairs Refer to 14 FUEL SYSTEM FUEL DELIVERY STANDARD PROCEDURE WARNING WRAP SHOP TOWELS AROU...

Page 506: ...manifold gasket on cylinder head mounting surface piloting on the 2 attaching studs 4 Loosely position manifold in engine compart ment 5 Insert engine wiring harness between middle intake runners 6 Co...

Page 507: ...0 is a welded con struction using lightweight tubular steel with stamped plate steel mounting flanges The manifold attaches to the cylinder head REMOVAL 1 Disconnect negative cable from battery 2 Rais...

Page 508: ...nnector and harness clip 5 Install speed control vacuum reservoir if equipped Refer to 8 ELECTRICAL SPEED CON TROL VACUUM RESERVOIR INSTALLATION 6 Connect make up air hose on cylinder head cover port...

Page 509: ...engine weight 5 Remove right engine mount to engine mount bracket bolt 6 Remove power steering pump assembly and set aside 7 Remove right engine mount bracket Refer to 9 ENGINE ENGINE MOUNTING ENGINE...

Page 510: ...N m 105 in lbs 2 Install engine front mount bracket Refer to 9 ENGINE ENGINE MOUNTING ENGINE MOUNT BRACKET INSTALLATION 3 Install right side engine mount to engine mount bracket bolt 4 Remove jack fro...

Page 511: ...mount bracket Fig 19 Refer to 9 ENGINE ENGINE MOUNTING EN GINE MOUNT BRACKET REMOVAL 10 Remove the timing belt front cover Fig 20 CAUTION Align camshaft and crankshaft timing marks before removing the...

Page 512: ...timing belt cover Fig 24 3 Move crankshaft to 1 2 mark before TDC Fig 25 for belt installation 4 Install the timing belt Starting at the crank shaft go around the water pump sprocket and then around...

Page 513: ...ioner up against the pulley pivot bracket and tighten tensioner bolts to 31 N m 23 ft lbs Fig 27 Fig 22 TENSIONER PULLEY ASSEMBLY 1 BRACKET 2 PULLEY BOLT 3 PULLEY 4 PULLEY PIVOT BRACKET 5 PIVOT BOLT D...

Page 514: ...NG ACCESSORY DRIVE DRIVE BELTS INSTALLATION 23 Install right inner splash shield 24 Lower vehicle and perform camshaft and crankshaft timing relearn procedure as follows Connect the DRB scan tool to t...

Page 515: ...ProCarManuals com 2001 NEON...

Page 516: ...ALLATION 17 GEAR SHIFT CABLE REMOVAL 17 INSTALLATION 19 ADJUSTMENTS 20 A578 MANUAL TRANSMISSION DIAGNOSIS AND TESTING COMMON PROBLEM CAUSES The majority of transaxle malfunctions are a result of Insuf...

Page 517: ...d 2 Disconnect both battery cables remove battery hold down clamp and bolt and remove battery 3 Remove air cleaner throttle body assy Fig 1 as follows a Disconnect proportional purge solenoid PPS and...

Page 518: ...nding brace Fig 6 16 Remove bellhousing dust cover Fig 6 17 Remove the right engine to transaxle lateral bending brace Fig 7 18 Remove starter motor Fig 8 19 Remove drive plate to clutch module bolts...

Page 519: ...Bending Brace and Structural Collar Typical 1 LATERAL BENDING BRACE 2 STRUCTURAL COLLAR 3 DUST COVER Fig 7 Right Lateral Bending Brace Removal Installation Typical 1 TRANSAXLE 2 ENGINE 3 LATERAL BENDI...

Page 520: ...d torque to 88 N m 65 ft lbs torque 6 Install starter motor and tighten bolts to 54 N m 40 ft lbs torque Make sure to fasten ground cable to upper starter bolt as shown in Fig 8 7 Connect starter elec...

Page 521: ...ables to the air cleaner throttle body assy b Install assy into position making sure the air cleaner locating slot is engaged to the battery bracket tab and tighten fasteners to 14 N m 120 in lbs torq...

Page 522: ...60 Vertical Bending Strut to Engine 108 80 Vertical Bending Strut to Trans 108 80 NV T350 A 578 MANUAL TRANSAXLE FLUID FILL TRANSAXLE METRIC MEASURE U S MEASURE NV T350 2 4 2 7 Liters 2 5 2 8 Quarts...

Page 523: ...4628 Seal Remover C 4680 Seal Installer C 4992 Torque Tool Adapter C 4996 Installer L 4410 Special Jaw Set L 4518 Bearing Splitter 1130 Driver 6342 21s 8 A578 MANUAL TRANSMISSION PL A578 MANUAL TRANSM...

Page 524: ...isconnect Tool 6638A Seal Installer 6709 Bearing Remover 6768 Bench Fixture 6785 Remover 6786 Remover 6787 Fig 12 Remove Differential Bearing Cone from Diff Case Side 1 SPECIAL TOOL C 293 PA 2 SPECIAL...

Page 525: ...USE 4 PIECES 3 DIFFERENTIAL ASSEMBLY 4 DIFFERENTIAL BEARING CONE 5 SPECIAL TOOL C 4996 NOTE POSITION Fig 14 Remove Ring Gear Bolts and Ring Gear 1 SPEEDOMETER DRIVE GEAR 2 BEARING 3 RING GEAR 4 RING...

Page 526: ...AR Fig 18 Retaining Pin Removed 1 DIFFERENTIAL ASSEMBLY 2 SPEEDOMETER DRIVE GEAR 3 PINION SHAFT RETAINING PIN Fig 19 Pinion Shaft Removal 1 DIFFERENTIAL ASSEMBLY 2 PINION SHAFT 3 SPEEDOMETER DRIVE GEA...

Page 527: ...gs to ring gear and case side Fig 24 Fig 25 6 Install speedometer drive gear to case Fig 26 Fig 21 Differential Components 1 DIFFERENTIAL ASSEMBLY 2 PINION SHAFT 3 SPEEDOMETER DRIVE GEAR 4 SIDE GEAR T...

Page 528: ...ig 25 Install Differential Bearing Cone to Ring Gear Side 1 ARBOR PRESS RAM 2 BEARING CONE 3 SPECIAL TOOL HANDLE C 4171 4 SPECIAL TOOL L 4410 5 DIFFERENTIAL ASSEMBLY Fig 26 Speedometer Drive Gear 1 SP...

Page 529: ...checked using the same procedure CAUTION Side gear end play must be within 0 001 to 0 013 inch Five select thrust washers are avail able 0 027 0 032 0 037 0 042 and 0 047 inch Fig 28 Drive Gear Press...

Page 530: ...direction Roll differential assembly back and forth a number of times This will settle the bearings Zero the dial indicator To obtain end play readings apply a medium load in an upward direction while...

Page 531: ...5 Remove selector cable retaining clip and dis connect from shift lever Fig 37 6 Remove four shifter assy to floor pan nuts and remove shifter from vehicle Fig 38 Fig 34 Gearshift Knob Boot Removal 1...

Page 532: ...om center console 3 Push down on knob and rotate clockwise to remove gearshift boot knob assy Fig 39 4 Remove the center console assembly as shown in Fig 40 5 Remove crossover cable retaining clip and...

Page 533: ...cable isolator bushings Remove cable retaining clips and remove cables from bracket Fig 44 Fig 41 Crossover Cable at Shifter Assembly 1 GROMMET PLATE NUT 2 SHIFTER 3 CROSSOVER CABLE 4 CLIP Fig 42 Sele...

Page 534: ...nstall and tighten the three grommet plate to floor pan nuts to 6 N m 50 in lbs torque 9 Install selector cable to shifter lever and secure cable to shifter bracket Install clip Fig 42 10 Install cros...

Page 535: ...ighten fasteners to 14 N m 120 in lbs torque 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 I...

Page 536: ...place the shifter in 3rd or 4th gear if necessary Torque adjust ment screw to 8 N m 70 in lbs Care must be taken to avoid moving the shift mechanism off center during screw tightening 6 Install cente...

Page 537: ...ion to check for slipping and any variation in shifting If vehicle operates at high speeds but has poor acceleration the converter s overrunning clutch may be slipping If acceleration is normal but hi...

Page 538: ...nation can be used to detect any unit that slips and to confirm proper operation of good units Road testing can usually diagnose slip ping units although the actual cause of the problem may not be det...

Page 539: ...ft End Play using End Play Set 8266 1 TOOL 8266 8 2 TOOL 8266 2 3 TOOL C 3339 Fig 2 Transaxle Oil Pan Bolts 1 TRANSAXLE OIL PAN 2 OIL PAN BOLTS Fig 3 Transaxle Oil Pan 1 TRANSAXLE OIL PAN 2 OIL FILTER...

Page 540: ...bypass valve and seal Fig 8 Fig 5 Oil Filter and Gasket 1 OIL FILTER 2 GASKET 3 VALVE BODY Fig 6 Parking Rod E Clip 1 VALVE BODY 2 SCREWDRIVER 3 E CLIP 4 PARKING ROD Fig 7 Parking Rod 1 VALVE BODY 2 P...

Page 541: ...p ring Fig 12 Fig 9 Valve Body Attaching Bolts 1 VALVE BODY 2 VALVE BODY ATTACHING BOLTS 7 3 GOVERNOR TUBES Fig 10 Valve Body and Governor Tubes 1 VALVE BODY ASSEMBLY 2 GOVERNOR TUBES Fig 11 Loosen Lo...

Page 542: ...d Servo 1 SERVO PISTON 2 SPRING AND RETAINER Fig 14 Accumulator Snap Ring 1 ACCUMULATOR PLATE SNAP RING 2 SNAP RING PLIERS 3 ACCUMULATOR PLATE Fig 15 Accumulator Plate and Snap Ring 1 SNAP RING 2 ACCU...

Page 543: ...ock Nut 1 KICKDOWN BAND ADJUSTING SCREW Fig 18 Kickdown Band Adjusting Screw 1 KICKDOWN BAND ADJUSTING SCREW Fig 19 Kickdown Servo Snap Ring 1 SNAP RING 2 SNAP RING PLIERS 3 ACCUMULATOR PLATE 4 KICKDO...

Page 544: ...KDOWN LEVER 3 PISTON ROD 4 KICKDOWN SERVO PISTON Fig 22 Controlled Load Kickdown Servo 1 KICKDOWN PISTON 2 O RING 3 SNAP RING 4 PISTON ROD GUIDE 5 SNAP RING 6 O RING 7 PISTON RETURN SPRING 8 PISTON RO...

Page 545: ...Remove oil pump with slide hammer setup Fig 28 Inspect 1 thrust washer Fig 25 Parking Pawl Return Spring and Pivot Shaft 1 PARK PAWL 2 RETURN SPRING 3 NOTE SMALL DIAMETER TO REAR 4 PIVOT SHAFT Fig 26...

Page 546: ...FEED 2 PUMP GASKET 3 PUMP GASKET DIFFERENTIAL OIL FEED CUTOUT Fig 30 Kickdown Band and Strut 1 FRONT CLUTCH 2 KICKDOWN BAND 3 OIL RETURN AND FEED HOLE TO DIFFERENTIAL 4 STRUT Fig 31 Front Clutch Asse...

Page 547: ...3 Thrust Washer 1 OUTPUT SHAFT 2 SUN GEAR DRIVING SHELL 3 3 THRUST WASHER SELECT FIT Fig 34 Front Planetary Gear Snap Ring 1 FRONT PLANETARY GEAR SNAP RING 2 SNAP RING PLIERS 3 FRONT PLANETARY GEAR A...

Page 548: ...STEEL 2 7 SPACER STEEL 3 SUN GEAR 4 SUN GEAR DRIVING SHELL 5 SNAP RING Fig 38 No 9 Thrust Washer 1 9 THRUST WASHER 2 OUTPUT SHAFT 3 REAR PLANETARY GEAR ASSEMBLY Fig 39 Rear Planetary Gear Assembly 1...

Page 549: ...Assembly 1 OUTPUT SHAFT 2 OVERRUNNING CLUTCH CAM ASSEMBLY Fig 42 Overrunning Clutch Rollers and Spring 1 LOW REVERSE BAND 2 OVERRUNNING CLUTCH ROLLERS 8 3 OVERRUNNING CLUTCH SPRINGS 8 Fig 43 Low Reve...

Page 550: ...ystem transfer shaft and output shaft components Refer to 21 TRANSMISSION TRANS AXLE AUTOMATIC 31TH TRANSFER SYSTEM INSTALLATION 1 Install 11 thrust washer Fig 45 2 Install low reverse band Fig 46 Do...

Page 551: ...9 thrust washer Fig 50 Use petrola tum to secure 9 Install sun gear driving shell Fig 51 Fig 48 Proper Spring Roller Orientation 1 TOOL L 4440 2 SPRING 3 ROLLER 4 CONTACT AREA Fig 49 Rear Planetary G...

Page 552: ...netary gear splines or transaxle failure will result Fig 52 Front Planetary Gear Assembly 1 SUN GEAR 2 FRONT PLANETARY GEAR ASSEMBLY 3 6 THRUST WASHER Fig 53 Front Planetary Gear Snap Ring 1 FRONT PLA...

Page 553: ...y 19 Install oil pump to transaxle Fig 59 Torque bolts to 31 N m 275 in lbs Fig 56 Front Clutch Assembly 1 REAR CLUTCH ASSEMBLY 2 FRONT CLUTCH ASSEMBLY Fig 57 Kickdown Band and Strut 1 FRONT CLUTCH 2...

Page 554: ...60 Measure Input Shaft End Play using End Play Set 8266 1 TOOL 8266 8 2 TOOL 8266 2 3 TOOL C 3339 Fig 61 Parking Pawl Return Spring and Pivot Shaft 1 PARK PAWL 2 RETURN SPRING 3 NOTE SMALL DIAMETER TO...

Page 555: ...AP RING 6 O RING 7 PISTON RETURN SPRING 8 PISTON ROD 9 SEAL RINGS Fig 65 Kickdown Piston Return Spring and Piston 1 RETURN SPRING 2 KICKDOWN LEVER 3 PISTON ROD 4 KICKDOWN SERVO PISTON Fig 66 Kickdown...

Page 556: ...on for installation 31 Install accumulator snap ring Fig 71 Fig 68 Adjust Kickdown Band 1 KICKDOWN BAND ADJUSTING SCREW Fig 69 Accumulator Spring and Piston 1 ACCUMULATOR SPRING 2 ACCUMULATOR PISTON 3...

Page 557: ...y Fig 75 Make sure governor tubes are properly engaged to the transaxle case and valve body Fig 72 Install Retainer Spring and Servo 1 SERVO PISTON 2 SPRING AND RETAINER Fig 73 Low Reverse Servo Snap...

Page 558: ...l filter and gasket into position Fig 79 Fig 76 Valve Body Attaching Bolts 1 VALVE BODY 2 VALVE BODY ATTACHING BOLTS 7 3 GOVERNOR TUBES Fig 77 Cooler Bypass Valve and Seal 1 TRANSFER PLATE 2 BYPASS VA...

Page 559: ...immediately install and torque oil pan to case bolts Fig 82 to 19 N m 165 in lbs torque Fig 80 Oil Filter Screws 1 SCREWDRIVER HANDLE 2 SPECIAL TOOL L 4553 3 OIL FILTER SCREWS 2 4 OIL FILTER Fig 81 T...

Page 560: ...SCHEMATICS AND DIAGRAMS 31TH TRANSAXLE HYDRAULIC SCHEMATICS Drive First Half Throttle PL 31TH AUTOMATIC TRANSAXLE 21s 45 31TH AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 561: ...Drive Second Half Throttle 21s 46 31TH AUTOMATIC TRANSAXLE PL 31TH AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 562: ...Drive Third Not Locked Up PL 31TH AUTOMATIC TRANSAXLE 21s 47 31TH AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 563: ...Drive Third Lock Up 21s 48 31TH AUTOMATIC TRANSAXLE PL 31TH AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 564: ...Drive Kickdown Part Throttle PL 31TH AUTOMATIC TRANSAXLE 21s 49 31TH AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 565: ...Second Manual Closed Throttle 21s 50 31TH AUTOMATIC TRANSAXLE PL 31TH AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 566: ...Low Manual Closed Throttle PL 31TH AUTOMATIC TRANSAXLE 21s 51 31TH AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 567: ...Reverse 21s 52 31TH AUTOMATIC TRANSAXLE PL 31TH AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 568: ...ntial Assembly 0 7 1 4 N m 6 12 in lbs Output Shaft 0 0 3 N m 0 3 in lbs Transfer Shaft 0 051 0 254 mm 0 002 0 010 in end play Overall Drag At Output Hub 0 03 1 8 N m 3 16 in lbs CLUTCH CLEARANCES Des...

Page 569: ...in Sun Gear Front No 7 0 85 0 91 mm 0 033 0 036 in Sun Gear Rear No 8 0 85 0 91 mm 0 033 0 036 in Rear Carrier Nos 9 10 1 22 1 28 mm 0 0948 0 050 in Rev Drum No 11 1 55 1 60 mm 0 061 0 063 in TORQUE S...

Page 570: ...nsfer Plate 5 40 Screw Governor Counterweight 28 250 Screw Manual Valve Lever to Shaft 12 105 Screw Speedo Adapter to Extension Housing 7 60 Screw Valve Body to Transfer Plate 5 45 Nut Kickdown Band A...

Page 571: ...Press C 293 PA Pressure Gauge High C 3293SP Dial Indicator C 3339 Spring Compressor C 3575 A Band Adjusting Adapter C 3705 Oil Pump Puller C 3752 Throttle Setting Gauge C 3763 Seal Puller C 3981B 21s...

Page 572: ...earing Installer C 4637 Adapter C 4658 Torque Tool C 4995 Adapter C 4996 Remover Kit L 4406 Bearing Remover Cup L 4406 1 Bearing Remover Jaws L 4406 2 PL 31TH AUTOMATIC TRANSAXLE 21s 57 31TH AUTOMATIC...

Page 573: ...taller L 4408 Bearing Installer L 4410 Bearing Installer L 4411 Installer Adapter L 4429 3 Gear Checking Plate L 4432 Gear Removing Plate L 4434 Bearing Puller L 4435 21s 58 31TH AUTOMATIC TRANSAXLE P...

Page 574: ...Nut L 4439 Transfer Shaft Remover Installer L 4512 Bearing Cup Remover L 4517 Special Jaw Set L 4518 Installer L 4520 End Play Socket Set 8266 Bearing Splitter P 334 PL 31TH AUTOMATIC TRANSAXLE 21s 5...

Page 575: ...rear band is also a single wrap design the band does not completely encompass wrap the drum that it holds OPERATION The rear band holds the rear planet carrier sta tionary by being mounted around and...

Page 576: ...ial teardown assembly or if any of the following parts are replaced Transaxle case Differential carrier Differential bearing retainer Extension housing Differential bearing cups and cones 1 Position t...

Page 577: ...AL BEARING SHIM CHART SHIM THICKNESS MM 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 1 34 0 0528 1 38 0 0544 1 42 0 0560 1 46 0 0575...

Page 578: ...INSPECTION The aluminum governor valve and outer weight have a hard coating on them Check condition of this coating carefully Do not reuse either part if the coat ing is damaged Inspect the governor...

Page 579: ...r 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 Fig 91 Impeller 1 ENGINE FLEXPLATE 4 ENGINE ROTATION...

Page 580: ...center of the impeller and splined into the turbine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction Fig 92 Turbine 1 TURBINE...

Page 581: ...f the impel ler and turbine were mechanically locked together a zero slippage condition could be obtained A hydraulic piston was added to the turbine and a friction mate rial was added to the inside o...

Page 582: ...over run ning clutch of the stator locks and holds the stator from rotating With the stator locked the oil strikes the stator blades and is redirected into a helping direction before it enters the imp...

Page 583: ...oved creating an unstable condition The torque converter is a heavy unit Use caution when separating the torque converter from the transmission 3 Pull the torque converter forward until the cen ter hu...

Page 584: ...OIL PUMP DESCRIPTION 170 OPERATION 170 STANDARD PROCEDURE 170 OIL PUMP VOLUME CHECK 170 DISASSEMBLY 171 ASSEMBLY 172 PLANETARY GEARTRAIN DESCRIPTION 172 OPERATION 172 SEAL OIL PUMP REMOVAL 172 INSTALL...

Page 585: ...192 REMOVAL 193 DISASSEMBLY 195 ASSEMBLY 199 INSTALLATION 204 41TE AUTOMATIC TRANSAXLE TRANSAXLE IDENTIFICATION DESCRIPTION Fig 1 41TE Transaxle 21s 70 41TE AUTOMATIC TRANSAXLE PL ProCarManuals com 2...

Page 586: ...pack trans mission control relay etc The TCM also performs certain self diagnostic functions and provides comprehensive information sensor data DTC s etc which is helpful in proper diagnosis and repa...

Page 587: ...k for slipping and any variation in shifting If the vehicle operates properly at highway speeds but has poor acceleration the converter stator over running clutch may be slipping If acceleration is no...

Page 588: ...sition 3 Allow vehicle wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 30 mph 4 In second gear the underdrive clutch pressure should read 110 to 145 psi TEST TWO...

Page 589: ...filter or a stuck pressure regu lator valve 3 Clutch circuit leaks are indicated if pressures do not fall within the specified pressure range 4 If the overdrive clutch pressure is greater than 5 psi i...

Page 590: ...ed hole rear of case between 2 bolt holes Then look in the area where the low reverse piston contacts the first separator plate Watch carefully for the piston to move forward The piston should return...

Page 591: ...sor connector 7 Disconnect output speed sensor connector 8 Disconnect solenoid pressure switch assembly connector 9 Disconnect gearshift cable from manual valve 10 Disconnect gearshift cable from uppe...

Page 592: ...MODULE STANDARD PROCEDURE NOTE This procedure does not include final drive differential disassembly 1 Remove input and output speed sensors 2 Remove three 3 solenoid pressure switch assembly to case b...

Page 593: ...some accumulators will have two springs and others will have one spring The springs are color coded according to application and year When disassem bling mark accumulator spring location to ease asse...

Page 594: ...ATOR 3 SEAL RING 2 4 OVERDRIVE CLUTCH ACCUMULATOR Fig 16 Accumulator Underdrive 1 ACCUMULATOR PISTON UNDERDRIVE 2 RETURN SPRINGS 3 SEAL RING 4 SEAL RING Fig 17 Accumulator Overdrive 1 ACCUMULATOR PIST...

Page 595: ...this range a 4 thrust plate change is required Record indicator reading for reference upon reassembly Fig 19 Remove Low Reverse Accumulator Plug Cover 1 ADJUSTABLE PLIERS 2 PLUG Fig 20 Remove Low Rev...

Page 596: ...ransaxle failure has occurred the cooler bypass valve must be replaced Do not re use or attempt to clean valve Fig 23 Remove Pump Attaching Bolts 1 PUMP ATTACHING BOLTS 2 PUMP HOUSING Fig 24 Install T...

Page 597: ...mp Gasket 1 PUMP GASKET Fig 28 Remove Bypass Valve 1 COOLER BYPASS VALVE Fig 29 Remove Caged Needle Bearing 1 1 CAGED NEEDLE BEARING 2 NOTE TANGED SIDE OUT Fig 30 Remove Input Clutch Assembly 1 INPUT...

Page 598: ...of locking pliers and bolts to center the tool properly Fig 31 No 4 Thrust Plate 1 OVERDRIVE SHAFT ASSEMBLY 2 4 THRUST PLATE SELECT 3 3 DABS OF PETROLATUM FOR RETENTION Fig 32 Remove Front Sun Gear As...

Page 599: ...lutch pack for reassembly identification Fig 35 Remove 2 4 Clutch Retainer Snap Ring 1 TOOL 5058 2 SCREWDRIVER 3 SNAP RING 4 2 4 CLUTCH RETAINER Fig 36 2 4 Clutch Retainer 1 2 4 CLUTCH RETAINER 2 2 4...

Page 600: ...IVER 3 LOW REVERSE TAPERED SNAP RING TAPERED SIDE UP 4 OIL PAN FACE 5 LONG TAB Fig 40 Remove Low Reverse Reaction Plate 1 LOW REVERSE REACTION PLATE FLAT SIDE UP Fig 41 Remove One Disc 1 ONE DISC FROM...

Page 601: ...Reverse Clutch Pack 1 CLUTCH PLATES 5 2 CLUTCH DISCS 5 Fig 44 Remove Rear Cover Bolts 1 REAR COVER BOLTS 2 REAR COVER 3 USE SEALANT ON BOLTS Fig 45 Remove Rear Cover 1 REAR COVER 2 1 8 INCH BEAD OF MO...

Page 602: ...WASHER 3 NUT Fig 48 Remove Transfer Shaft Gear 1 SPECIAL TOOL L4407 6 2 TRANSFER SHAFT GEAR 3 SPECIAL TOOL L4407A Fig 49 Remove Transfer Shaft Gear and Select Shim 1 TRANSFER SHAFT GEAR 2 BEARING CUP...

Page 603: ...Cone 1 WRENCHES 2 TOOL 5048 WITH JAWS TOOL 5048 4 AND BUTTON TOOL L 4539 2 3 TRANSFER SHAFT GEAR Fig 52 Remove Transfer Shaft Bearing Cup 1 WRENCHES 2 TOOL 6062 3 TRANSFER SHAFT BEARING CUP RETAINER F...

Page 604: ...rup and strap Fig 58 Fig 55 Bearing Cup Removed 1 BEARING CUP 2 BEARING CONE 3 TRANSFER SHAFT 4 OIL BAFFLE 5 O RING Fig 56 Remove Transfer Shaft Bearing Cone 1 ARBOR PRESS RAM 2 TRANSFER SHAFT 3 TOOL...

Page 605: ...emove Output Gear Bolt 1 OUTPUT GEAR 2 TOOL 6259 Fig 60 Output Gear Bolt and Washer 1 OUTPUT GEAR 2 BOLT 3 CONED LOCK WASHER Fig 61 Remove Output Gear 1 OUTPUT GEAR 2 BUTTON TOOL 6055 3 WRENCHES 4 TOO...

Page 606: ...67 Fig 63 Remove Bearing Cone 1 TOOL 5048 WITH JAWS 5048 5 AND BUTTON L 4539 2 2 WRENCHES 3 OUTPUT GEAR Fig 64 Remove Rear Carrier Assembly 1 REAR CARRIER ASSEMBLY Fig 65 Remove Rear Carrier Bearing...

Page 607: ...E CLUTCH RETURN SPRING 2 SNAP RING INSTALL AS SHOWN 3 TOOL 6057 4 TOOL 5059 5 TOOL 5058 3 Fig 68 Remove Snap Ring 1 SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS AS SHOWN 2 SNAP RING PLIERS 3 TOOL 6...

Page 608: ...de Bracket 1 ANTIRACHET SPRING 2 GUIDE BRACKET 3 PIVOT SHAFT 4 PAWL Fig 72 Guide Bracket Disassembled 1 ANTIRATCHET SPRING 2 GUIDE BRACKET 3 SPLIT SLEEVE 4 SPACER 5 STEPPED SPACER 6 PAWL Fig 73 Remove...

Page 609: ...78 Fig 75 Remove Piston Retainer 1 LOW REVERSE CLUTCH PISTON RETAINER 2 GASKET Fig 76 Remove Piston Retainer Gasket 1 GASKET HOLES MUST LINE UP 2 LOW REVERSE CLUTCH PISTON RETAINER GASKET Fig 77 Remo...

Page 610: ...ust be performed Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE 1 Install both output bearing cups using Tool 5050 Fig 79 2 Install low reverse piston...

Page 611: ...PISTON RETAINER 2 SCREWDRIVER 3 TORX LOC SCREWS Fig 83 Install Low Reverse Clutch Piston 1 LOW REVERSE CLUTCH PISTON 2 D RING SEAL 3 D RING SEAL Fig 84 Guide Bracket Disassembled 1 ANTIRATCHET SPRING...

Page 612: ...install snap ring as shown in Fig 90 Fig 86 Pivot Shaft and Guide Bracket 1 ANTIRACHET SPRING 2 GUIDE BRACKET 3 PIVOT SHAFT 4 PAWL Fig 87 Install Anchor Shaft and Plug 1 GUIDE BRACKET ANCHOR SHAFT 2 P...

Page 613: ...TWEEN SPRING LEVERS AS SHOWN 2 SNAP RING PLIERS 3 TOOL 6057 Fig 91 Install Rear Carrier Bearing Cone 1 ARBOR PRESS RAM 2 TOOL 6053 3 NEW BEARING CONE 4 REAR CARRIER ASSEMBLY Fig 92 Install Rear Carrie...

Page 614: ...se measure output gear end play as shown in Fig 94 f Refer to the output gear bearing shim chart for the required shim to obtain proper bearing set ting g Use Tool 6259 to remove the output gear retai...

Page 615: ...m 0 010 in 4 22mm 0 166 in 4412825AB 0 74mm 0 029 in 3 74mm 0 147 in 4412813AB 0 28mm 0 011 in 4 18mm 0 165 in 4412824AB 0 76mm 0 030 in 3 70mm 0 146 in 4412812AB 0 30mm 0 012 in 4 14mm 0 163 in 44128...

Page 616: ...16 in thicker shim If the turning torque is too low install a 0 04 mm 0 0016 in thinner shim Repeat until the proper turning torque of 3 8 in lbs is obtained Fig 96 Install Output Gear 1 WRENCHES 2 TO...

Page 617: ...ap bolts to 23 N m 200 in lbs Fig 103 Fig 100 Install Stirrup 1 STIRRUP 2 OUTPUT GEAR RETAINING BOLT Fig 101 Install Strap Bolts 1 RETAINING STRAP 2 STIRRUP 3 RETAINING STRAP BOLTS Fig 102 Turn Stirru...

Page 618: ...inst Flats Of Bolts 1 RETAINING STRAP TABS 2 RETAINING STRAP 3 STIRRUP Fig 105 Install Transfer Shaft Bearing Cone 1 TOOL 6052 2 NEW BEARING CONE 3 TRANSFER SHAFT 4 ARBOR PRESS RAM Fig 106 Install Bea...

Page 619: ...2 TRANSFER SHAFT BEARING SNAP RING 3 TRANSFER SHAFT Fig 109 Install Transfer Shaft Bearing Cup Into Retainer 1 ARBOR PRESS RAM 2 HANDLE C 4171 3 TOOL 6061 4 TRANSFER SHAFT BEARING CUP RETAINER 5 USE R...

Page 620: ...mm 0 030 in 3 94mm 0 155 in 4412818AB 0 08mm 0 003 in 4 62mm 0 182 in 4412835AB 0 79mm 0 031 in 3 90mm 0 154 in 4412817AB 0 10mm 0 004 in 4 58mm 0 180 in 4412834AB 0 81mm 0 032 in 3 90mm 0 154 in 4412...

Page 621: ...0 53mm 0 021 in 4 18mm 0 165 in 4412824AB 1 24mm 0 049 in 3 46mm 0 136 in 4412806AB 0 56mm 0 022 in 4 14mm 0 163 in 4412823AB 1 27mm 0 050 in 3 42mm 0 135 in 4412805AB 0 58mm 0 023 in 4 10mm 0 161 in...

Page 622: ...0 004 in end play is obtained 36 Install a bead of Mopart Silicone Rubber Adhesive Sealant to transfer gear cover Fig 115 37 Install transfer gear cover to case bolts and torque to 20 N m 175 in lbs t...

Page 623: ...Fig 120 Fig 117 Install Low Reverse Clutch Pack 1 CLUTCH PLATES 5 2 CLUTCH DISCS 5 Fig 118 Install Low Reverse Reaction Plate Snap Ring 1 SCREWDRIVER 2 LOW REVERSE REACTION PLATE FLAT SNAP RING 3 DO N...

Page 624: ...ICKNESS 4799846AA 5 88 mm 0 232 in 4799847AA 6 14 mm 0 242 in 4799848AA 6 40 mm 0 252 in 4799849AA 6 66 mm 0 262 in 4799855AA 6 92 mm 0 273 in 44 Install 2 4 clutch pack Fig 124 staggering clutch plat...

Page 625: ...te Pads 1 PILOT PADS 2 LUGS Fig 126 Proper Orientation of 2 4 Clutch Retainer and Spring 1 NOTE POSITION 2 RETURN SPRING 3 2 4 CLUTCH RETAINER Fig 127 2 4 Clutch Retainer 1 2 4 CLUTCH RETAINER 2 2 4 C...

Page 626: ...nnulus assembly and 6 needle bearing Fig 131 51 Install front sun gear assembly and 4 thrust washer Fig 132 Fig 129 Check 2 4 Clutch Clearance 1 DIAL INDICATOR 2 HOOK TOOL 3 DIAL INDICATOR TIP TOOL 62...

Page 627: ...n in Fig 136 e Measure the input shaft end play with the transaxle in the vertical position Input shaft end play must within 0 005 to 0 025 inch For exam ple if end play reading is 0 055 inch select N...

Page 628: ...15mm 0 124 in 4446601 3 38mm 0 133 in 53 Install input clutch assembly Fig 137 54 Install 1 caged needle bearing Fig 138 CAUTION The cooler bypass valve must be replaced if transaxle failure has occu...

Page 629: ...case bolts and torque to 27 N m 20 ft lbs Fig 142 Fig 139 Install Cooler Bypass Valve 1 COOLER BYPASS VALVE Fig 140 Install Oil Pump Gasket 1 PUMP GASKET Fig 141 Install Oil Pump 1 OIL PUMP 2 GASKET...

Page 630: ...underdrive and overdrive accumulators Fig 146 Fig 147 Fig 148 Fig 143 Install Low Reverse Accumulator 1 ACCUMULATOR PISTON 2 SEAL RINGS 3 RETURN SPRINGS 4 NOTE NOTCH Fig 144 Install Low Reverse Accum...

Page 631: ...cumulator Overdrive 1 ACCUMULATOR PISTON OVERDRIVE 2 RETURN SPRING 3 SEAL RING 4 SEAL RING Fig 148 Install Underdrive and Overdrive Accumulators 1 RETURN SPRING 2 UNDERDRIVE CLUTCH ACCUMULATOR 3 SEAL...

Page 632: ...nstall and tighten solenoid pressure switch assembly to transaxle case bolts to 12 N m 110 in lbs Fig 154 Fig 151 Install Oil Filter 1 OIL FILTER 2 O RING Fig 152 Install Oil Pan 1 OIL PAN 2 1 8 INCH...

Page 633: ...le case bolts to 108 N m 80 ft lbs Torque brace to engine bedplate bolt to 54 N m 40 ft lbs Torque brace to intake manifold bolt to 28 N m 200 in lbs 10 Install structural collar 11 Install power stee...

Page 634: ...SCHEMATICS AND DIAGRAMS 41TE TRANSAXLE HYDRAULIC SCHEMATICS Park Neutral Speed Under 8 mph PL 41TE AUTOMATIC TRANSAXLE 21s 119 41TE AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 635: ...Neutral Speed Over 8 mph 21s 120 41TE AUTOMATIC TRANSAXLE PL 41TE AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 636: ...Reverse PL 41TE AUTOMATIC TRANSAXLE 21s 121 41TE AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 637: ...Reverse Block Shift to Reverse w Speed Over 8 Mph 21s 122 41TE AUTOMATIC TRANSAXLE PL 41TE AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 638: ...First Gear PL 41TE AUTOMATIC TRANSAXLE 21s 123 41TE AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 639: ...Second Gear 21s 124 41TE AUTOMATIC TRANSAXLE PL 41TE AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 640: ...Second Gear EMCC PL 41TE AUTOMATIC TRANSAXLE 21s 125 41TE AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 641: ...Direct Gear 21s 126 41TE AUTOMATIC TRANSAXLE PL 41TE AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 642: ...Direct Gear EMCC PL 41TE AUTOMATIC TRANSAXLE 21s 127 41TE AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 643: ...Direct Gear CC On 21s 128 41TE AUTOMATIC TRANSAXLE PL 41TE AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 644: ...Overdrive PL 41TE AUTOMATIC TRANSAXLE 21s 129 41TE AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 645: ...Overdrive EMCC 21s 130 41TE AUTOMATIC TRANSAXLE PL 41TE AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 646: ...Overdrive CC On PL 41TE AUTOMATIC TRANSAXLE 21s 131 41TE AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 NEON...

Page 647: ...Overall Drag At Output Hub 0 3 1 9 N m 3 16 in lbs CLUTCH CLEARANCES DESCRIPTION METRIC STANDARD Low Rev Clutch Select Reaction Plate 0 89 1 47 mm 0 035 0 058 in Two Four Clutch No Selection 0 76 2 64...

Page 648: ...trap 23 17 Bolt Oil Pump to Case 27 20 Bolt Reaction Support to Case 27 20 Bolt Solenoid Pressure Switch Assy to Case 12 110 Bolt Torque Converter to Driveplate 75 55 Bolt Transfer Gear Cover 20 175 B...

Page 649: ...ressure Gauge High C 3293SP Dial Indicator C 3339 Oil Pump Puller C 3752 Seal Puller C 3981B Universal Handle C 4171 Seal Installer C 4193A Adapter C 4996 21s 134 41TE AUTOMATIC TRANSAXLE PL 41TE AUTO...

Page 650: ...Bearing Installer L 4410 Gear Checking Plate L 4432 Bearing Puller L 4435 Differential Tool L 4436A Special Jaw Set L 4518 Installer L 4520 PL 41TE AUTOMATIC TRANSAXLE 21s 135 41TE AUTOMATIC TRANSAXLE...

Page 651: ...dapter L 4559 Adapter L 4559 2 Bearing Splitter P 334 Puller Set 5048 Remover Installer 5049 A Installer 5050A Installer 5052 21s 136 41TE AUTOMATIC TRANSAXLE PL 41TE AUTOMATIC TRANSAXLE Continued Pro...

Page 652: ...sor 5058A Compressor 5059 A Installer 5067 Pliers 6051 Installer 6052 Installer 6053 Button 6055 Plate 6056 PL 41TE AUTOMATIC TRANSAXLE 21s 137 41TE AUTOMATIC TRANSAXLE Continued ProCarManuals com 200...

Page 653: ...6057 Installer 6061 Remover 6062 A Holder 6259 Bolt 6260 Installer 6261 Tip 6268 Remover Installer 6301 21s 138 41TE AUTOMATIC TRANSAXLE PL 41TE AUTOMATIC TRANSAXLE Continued ProCarManuals com 2001 N...

Page 654: ...6302 Installer 6536 A Cooler Flusher 6906A Puller 7794 A End Play Socket Set 8266 Input Clutch Pressure Fixture 8391 PL 41TE AUTOMATIC TRANSAXLE 21s 139 41TE AUTOMATIC TRANSAXLE Continued ProCarManua...

Page 655: ...crews Fig 157 OPERATION The function of an accumulator is to cushion the application of a frictional clutch element When pres surized fluid is applied to a clutch circuit the appli cation force is dam...

Page 656: ...ves the rear sun gear OVERDRIVE CLUTCH The overdrive clutch is hydraulically applied in third direct and overdrive gears by pressurized fluid against the overdrive reverse piston When the over drive c...

Page 657: ...e within the differ ential are the differential bearing cups and cones If any other part fails within the differential you must replace the differential assembly along with the transfer shaft The tran...

Page 658: ...ol 5048 5048 4 Collets and L 4539 2 Button to remove the differential bear ing cone on the bearing retainer side Fig 166 Fig 167 Fig 168 Fig 163 Remove Bearing Retainer 1 DIFFERENTIAL BEARING RETAINER...

Page 659: ...nd Collets at Differential Bearing Ring Gear Side 1 SPECIAL TO0L 5048 2 DIFFERENTIAL 3 SPECIAL TOOL 5048 4 Fig 168 Remove Differential Bearing Cone Ring Gear Side 1 SPECIAL TOOL 5048 2 RING GEAR Fig 1...

Page 660: ...tall differential bearing to differential extension housing side Fig 171 2 Using Miller Special Tool 5052 and C 4171 install differential bearing to differential bearing retainer side 3 Using Miller S...

Page 661: ...the P Park and N Neutral positions Place the selector lever in P Park to be sure that the fluid level check is accurate The engine should be running at idle speed for at least one minute with the vehi...

Page 662: ...e vent where it may be mistaken for a leak FLUID CONDITION Along with fluid level it is important to check the condition of the fluid When the fluid smells burned and is contaminated with metal or fri...

Page 663: ...olts to 19 N m 165 in lbs 5 Pour four quarts of Mopart ATF 4 Automatic Transmission Fluid Type 9602 through the dipstick opening 6 Start engine and allow to idle for at least one minute Then with park...

Page 664: ...mount to bring the transaxle fluid level to 3mm 1 8 in below the lowest mark on the dip stick Fig 179 9 Recheck the fluid level after the transaxle has reached normal operating temperature 180 F Refer...

Page 665: ...trol if equipped cables after the assy is removed from position Remove air cleaner assembly from vehi cle 8 Remove battery tray from bracket 9 Disconnect shifter cable from shift lever and remove from...

Page 666: ...le as follows a Place gearshift lever in the PARK P position b Loosen shift cable adjustment screw Fig 188 c Verify transaxle is in the PARK P position and the shifter lever is in gated PARK d Tighten...

Page 667: ...3 Adjust gearshift cable as follows a Place gearshift lever in the PARK P posi tion b Loosen shift cable adjustment screw Fig 191 c Move transaxle manual lever to the PARK Verify transaxle is in PARK...

Page 668: ...CLUTCH ASSEMBLY DISASSEMBLY 1 Mount input clutch assembly to Input Clutch Pressure Fixture Tool 8391 2 Tap down reverse clutch reaction plate to release pressure from snap ring Fig 193 Fig 191 Gearsh...

Page 669: ...Clutch Snap Ring 1 REACTION PLATE 2 SCREWDRIVER 3 REVERSE CLUTCH SNAP RING SELECT Fig 195 Pry Reverse Clutch Reaction Plate 1 REVERSE CLUTCH REACTION PLATE 2 SCREWDRIVER 3 SCREWDRIVER Fig 196 Reverse...

Page 670: ...Ring 1 OD REVERSE PRESSURE PLATE 2 SCREWDRIVER 3 OD REVERSE PRESSURE PLATE SNAP RING Fig 199 OD Reverse Reaction Plate 1 OD REVERSE PRESSURE PLATE STEP SIDE DOWN 2 STEP SIDE DOWN Fig 200 Waved Snap R...

Page 671: ...E 2 OVERDRIVE SHAFT ASSEMBLY 3 OVERDRIVE CLUTCH DISC Fig 203 3 4 Thrust Washers 1 3 THRUST PLATE 3 TABS 2 OD SHAFT ASSEMBLY 3 4 THRUST PLATE 3 SLOTS Fig 204 Underdrive Shaft Assembly 1 3 THRUST WASHER...

Page 672: ...nap ring Fig 209 Fig 206 OD UD Reaction Plate Tapered Snap Ring 1 OVERDRIVE UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING 2 SCREWDRIVER DO NOT SCRATCH REACTION PLATE Fig 207 OD UD Reaction Plat...

Page 673: ...pring retainer Fig 212 20 Remove UD clutch piston Fig 213 Fig 210 Underdrive Clutch Pack 1 CLUTCH PLATE 2 ONE UD CLUTCH DISC 3 CLUTCH DISC Fig 211 UD Spring Retainer Snap Ring 1 SNAP RING PLIERS 2 ARB...

Page 674: ...INPUT SHAFT 2 INPUT HUB SNAP RING TAPERED SIDE UP WITH TABS IN CAVITY 3 SNAP RING PLIERS Fig 215 Tap on Input Hub 1 INPUT SHAFT AND HUB ASSEMBLY 2 PLASTIC HAMMER Fig 216 Input Hub Removed 1 INPUT SHAF...

Page 675: ...ETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING 2 SCREWDRIVER 3 SNAP RING 4 SPECIAL TOOL 6057 5 OD REVERSE PISTON 6 RETURN SPRING Fig 219 Snap Ring and Return Spring 1 OD REVERSE PISTON 2 RETU...

Page 676: ...RAM 3 INPUT SHAFT HUB ASSEMBLY Fig 223 Install Input Shaft Snap Ring 1 INPUT SHAFT 2 SCREWDRIVER DO NOT SCRATCH BEARING SURFACE 3 SNAP RING 4 O RINGS 5 SEALS Fig 224 Return Spring and Snap Ring 1 OD...

Page 677: ...se Piston 1 PUSH DOWN TO INSTALL OVERDRIVE REVERSE PISTON 2 INPUT CLUTCHES RETAINER Fig 227 Install Input Shaft Hub Assembly 1 PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY ROTATE TO ALIGN SPLINES 2 O...

Page 678: ...233 Fig 230 Seal Compressor Special Tool 5067 1 PISTON RETURN SPRING 2 SPECIAL TOOL 5067 3 INPUT SHAFT CLUTCHES RETAINER ASSEMBLY Fig 231 UD Return Spring and Retainer 1 UNDERDRIVE SPRING RETAINER 2 S...

Page 679: ...re press down and hold near indicator the UD clutch pack with screw driver or suitable tool and zero dial indicator Fig 241 When releasing pressure on clutch pack indica tor reading should advance 0 0...

Page 680: ...TAPERED SNAP RING 2 SCREWDRIVER Fig 239 Input Clutch Assembly on Pressure Fixture Tool 8391 1 INPUT CLUTCH ASSEMBLY 2 INPUT CLUTCH PRESSURE FIXTURE 8391 Fig 240 Set Up Dial Indicator to Measure UD Clu...

Page 681: ...nd apply 30 psi 206 kPa air pressure to the overdrive clutch hose on Tool 8391 Measure and record OD clutch pack measure ment in four 4 places 90 apart 27 Take average of four measurements and com par...

Page 682: ...ool and zero dial indicator Fig 252 When releasing pressure indicator should advance 0 005 0 010 as clutch pack relaxes 34 Apply 30 psi 206 kPa air pressure to the reverse clutch hose on Tool 8391 Mea...

Page 683: ...To complete the assembly reverse clutch and overdrive clutch must be removed 37 Install the 2 needle bearing Fig 253 Fig 250 Pry Up Reaction Plate to Seat Against Snap Ring 1 SCREWDRIVER 2 SNAP RING 3...

Page 684: ...se clutch as shown Rechecking these clutch clearances is not necessary Fig 254 Install Underdrive Shaft Assembly 1 UNDERDRIVE SHAFT ASSEMBLY 2 2 NEEDLE BEARING Fig 255 Install No 3 Thrust Washer 1 3 T...

Page 685: ...602 The following procedure is to check oil pump output volume 1 Using hose cutters or a suitable blade cut the to cooler Fig 259 line off flush with the cooler inlet fitting and place a collection co...

Page 686: ...of Plastigage across both pump gears 9 Align the Plastigage to a flat area on the reac tion shaft support housing 10 Install the reaction shaft to the pump hous ing Tighten the bolts to 27 N m 20 ft l...

Page 687: ...put and holding clutches drive or lock different planetary members to change output ratio or direction SEAL OIL PUMP REMOVAL 1 Remove transaxle from vehicle Refer to 21 TRANSMISSION TRANSAXLE AUTOMATI...

Page 688: ...4 Remove shifter bezel Fig 269 5 Disconnect the shifter ignition interlock cable from the shifter lever and bracket as shown in Fig 270 Remove the cable core end from the plastic cam of the shifter m...

Page 689: ...or from the interlock cable Fig 273 Fig 269 Shifter Bezel Removal Installation 1 BEZEL 2 SCREW 4 Fig 270 Interlock Cable at Shifter Assembly 1 INTERLOCK CABLE 2 SHIFTER ASSEMBLY Fig 271 Steering Colum...

Page 690: ...olumn and around to gear shifter assembly 2 Turn the ignition key to the OFF or ON RUN position Fig 274 3 Install the interlock cable into the interlock housing at the steering column Fig 276 Verify t...

Page 691: ...interlock system operation as follows ACTION EXPECTED RESPONSE 1 Turn key to the 9OFF9 position 1 Shifter CAN be shifted out of park 2 Turn key to the 9ON RUN9 position 2 Shifter CANNOT be shifted out...

Page 692: ...all steering column lower cover Fig 277 SHIFT INTERLOCK SYSTEM DIAGNOSIS AND TESTING BRAKE TRANSMISSION SHIFT INTERLOCK The following chart describes the normal operation of the Brake Transmission Shi...

Page 693: ...s response then system repair and or adjustment is necessary ACTION EXPECTED RESPONSE 1 Turn key to the 9OFF9 position 1 Shifter CAN be shifted out of park 2 Turn key to the 9ON RUN9 position 2 Shifte...

Page 694: ...gh a single wire The TCM energizes or operates the solenoids individ ually by grounding the return wire of the solenoid needed When a solenoid is energized the solenoid valve shifts and a fluid passag...

Page 695: ...gear with the engine speed above 1000 rpm the TCM momentarily turns on ele ment pressure to the 2 4 and or OD clutch circuits to identify that the appropriate switch has closed If it doesn t close it...

Page 696: ...or and torque to 4 N m 35 in lbs 6 Install air cleaner throttle body assembly 7 Connect battery negative cable 8 If solenoid pressure switch assembly was replaced perform TCM Quick Learn procedure Ref...

Page 697: ...peed ratio REMOVAL 1 Disconnect battery negative cable 2 Remove air cleaner throttle body assembly 3 Disconnect input speed sensor connector 4 Unscrew and remove input speed sensor Fig 292 5 Inspect s...

Page 698: ...ED SIGNAL The vehicle speed signal is taken from the Output Speed Sensor The TCM converts this signal into a pulse per mile signal and sends it to the PCM The PCM in turn sends the vehicle speed messa...

Page 699: ...engagement also provides reduced transmission fluid temperatures The con verter clutch engages in third gear The torque con verter hub drives the transmission oil fluid pump The torque converter is a...

Page 700: ...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 Fig 300 Impeller 1 ENGINE FLEXPLATE 4 ENGINE ROTATION...

Page 701: ...enter of the impeller and splined into the turbine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction Fig 301 Turbine 1 TURBINE...

Page 702: ...the impel ler and turbine were mechanically locked together a zero slippage condition could be obtained A hydraulic piston was added to the turbine and a friction mate rial was added to the inside of...

Page 703: ...ver run ning clutch of the stator locks and holds the stator from rotating With the stator locked the oil strikes the stator blades and is redirected into a helping direction before it enters the impe...

Page 704: ...The torque converter is a heavy unit Use caution when separating the torque converter from the transmission 3 Pull the torque converter forward until the cen ter hub clears the oil pump seal 4 Separa...

Page 705: ...ge is greater than 3 volts TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor TRS is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the...

Page 706: ...ition exists If the thermistor circuit fails the TCM will revert to calculated oil temperature usage CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated tem...

Page 707: ...ration and design REGULATOR VALVE The regulator valve controls hydraulic pressure in the transaxle It receives unregulated pressure from the pump which works against spring tension to maintain oil at...

Page 708: ...he TCM Quick Learn Procedure must be per formed Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE 1 Disconnect battery negative cable 2 Remove air cleaner...

Page 709: ...8 CAUTION The valve body manual shaft pilot may distort and bind the manual valve if the valve body is mishandled or dropped Fig 314 Oil Pan 1 OIL PAN 2 1 8 INCH BEAD OF RTV SEALANT 3 OIL FILTER Fig 3...

Page 710: ...320 3 Remove Manual Shaft Rooster Comb and Transmission Range Sensor Fig 321 Fig 318 Valve Body Removal Installation 1 VALVE BODY Fig 319 Manual Shaft Seal 1 SEAL 2 MANUAL SHAFT Fig 320 Remove Transmi...

Page 711: ...eck balls Fig 322 2 4 Accumulator Retaining Plate 1 2 4 ACCUMULATOR RETAINING PLATE 2 DETENT SPRING Fig 323 2 4 Accumulator Assembly 1 VALVE BODY 2 RETAINER PLATE 3 DETENT SPRING 4 SPRINGS 5 SEALS 6 P...

Page 712: ...329 12 Remove check balls Fig 330 Fig 326 Remove Oil Screen 1 OIL SCREEN Fig 327 Remove Overdrive Clutch 5 Check Valve 1 OVERDRIVE CLUTCH 5 CHECK VALVE Fig 328 Remove Separator Plate 1 SEPARATOR PLATE...

Page 713: ...dentification Fig 330 Ball Check Location 1 4 BALL CHECK LOCATION 2 2 BALL CHECK LOCATION 3 RETAINER 4 3 BALL CHECK LOCATION 5 LOW REVERSE SWITCH VALVE 6 T C LIMIT VALVE 21s 198 41TE AUTOMATIC TRANSAX...

Page 714: ...nd springs as shown in Fig 334 2 Install regulator valve spring retainer Fig 335 3 Install dual retainer plate using Tool 6301 Fig 336 4 Verify that all retainers are installed as shown in Fig 337 Ret...

Page 715: ...H VALVE 7 SOLENOID SWITCH VALVE 4 CONVERTER CLUTCH CONTROL VALVE 8 REGULATOR VALVE Fig 335 Install Regulator Valve Spring Retainer using Tool 6302 1 TOOL 6302 2 RETAINER Fig 336 Install Dual Retainer...

Page 716: ...ATION 3 RETAINER 4 3 BALL CHECK LOCATION 5 LOW REVERSE SWITCH VALVE 6 T C LIMIT VALVE Fig 339 Install Thermal Valve 1 THERMAL VALVE Fig 337 Valve Retainer Location 1 RETAINER 2 RETAINER PL 41TE AUTOMA...

Page 717: ...all transfer plate to valve body and sepa rator plate Make sure oil screen and 5 check valve do not bind Fig 343 Fig 340 Install Separator Plate 1 SEPARATOR PLATE 2 VALVE BODY Fig 341 Install Overdriv...

Page 718: ...44 Install Valve Body to Transfer Plate Screws 1 SCREW 24 2 TRANSFER PLATE 3 VALVE BODY Fig 345 2 4 Accumulator Assembly 1 VALVE BODY 2 RETAINER PLATE 3 DETENT SPRING 4 SPRINGS 5 SEALS 6 PISTON Fig 34...

Page 719: ...L MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE 1 Install valve body assembly to transaxle Fig 350 Install and torque valve body to transaxle case bolts Fig 351 to 12 N m 105 in lbs Fig 348 I...

Page 720: ...sensor connector 6 Install manual valve lever to manual shaft 7 Install gearshift cable to manual valve lever 8 Install air cleaner throttle body assembly 9 Connect battery negative cable 10 Fill tra...

Page 721: ...ProCarManuals com 2001 NEON...

Page 722: ...t possible to remove a fastener without damaging a component or body cut or break the fastener and use a new one when installing the component Never pry or pound on a plastic or pressed board trim com...

Page 723: ...bsorbing system used to protect the occupants in collisions The exterior sheet metal is repairable and adjustable for fit and finish Welded and bonded component systems are adjustable as a system Trim...

Page 724: ...ront seat track to cushion frame bolt 12 9 Front seat back 40 30 Front seat back recliner to seat back 12 9 Front door hinge to hinge pillar bolt 28 21 Front door hinge to door nuts and bolt 28 21 Fro...

Page 725: ...ID HATCH LIFTGATE TAILGATE COVER REMOVAL 2 Unclip cable and handle assembly Fig 1 INSTALLATION 1 Attach emergency release cable clip to the latch stud 2 Install the decklid cover Refer to 23 BODY DECK...

Page 726: ...INSTALLATION 1 Clean panel surface with isopropy alcohol 2 Remove paper carrier and align badgeing tape to reference points or adjacent panel 3 Install and press securely using a plastic spreader to e...

Page 727: ...emove the four nuts and remove the spoiler Fig 2 INSTALLATION 1 Install the spoiler and nuts 2 Tighten nuts to 3 N m 30 in lbs 3 Install the decklid cover Refer to 23 BODY DECKLID HATCH LIFTGATE TAILG...

Page 728: ...instrument panel top cover Refer to Body Instrument Panel Instrument Panel Top Cover Removal 5 Gently pull up on cluster bezel and remove from vehicle 6 Remove two screws Then gently pull rearward on...

Page 729: ...anel Fig 5 If replacing instrument panel transfer parts Fig 4 as necessary INSTALLATION If replacing instrument panel transfer parts from old instrument panel as necessary 1 With help on an assistant...

Page 730: ...nge Indicator Lamp Brake Interlock Cable ATX 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 PA...

Page 731: ...ower edge 27 Position the cluster bezel over mounting slots and firmly snap into place 28 Install the instrument panel top cover Refer to Body Instrument Panel Instrument Panel Top Cover Installation...

Page 732: ...control head 2 Remove both center A C outlet louvers Fig 5 by rolling downward and pulling out 3 Remove two screws retaining the top front of the center bezel up inside the center A C outlet duct 4 Us...

Page 733: ...lts to 40 N m 30 ft lbs torque 1 Position B pillar trim panel near B pillar 2 Feed seat belt turning loop and seat belt through trim panel 3 Align locating pins on backside of trim panel to mating hol...

Page 734: ...manual transmission 7 Lift console upward over gear selector and park brake handle 8 Remove console from vehicle INSTALLATION 1 Place floor console into position in vehicle 2 Install screws attaching...

Page 735: ...LE ASSEMBLY REMOVAL 17 INSTALLATION 17 CONTROL UNIT REMOVAL 17 INSTALLATION 17 DRIVE MOTOR REMOVAL 18 INSTALLATION 18 GLASS PANEL REMOVAL 18 ADJUSTMENTS 18 SUNSHADE REMOVAL 19 INSTALLATION 19 WIND DEF...

Page 736: ...voltage is detected at the control switches proceed with the following tests Before beginning diagnosis for wind noise or water leaks verify that the problem was not caused by releasing the control sw...

Page 737: ...on in tracks and mechanism re lube if necessary 3 Check for dirt debris in tracks clean and re lube 4 Cables ratchet at motor pinion Mechanism jammed fix mechanism and replace cables motor bracket Win...

Page 738: ...ON 1 With the aid of a helper position sunroof mod ule in vehicle 2 Install fasteners attaching sunroof module to vehicle roof and support braces Tighten all fasteners to 5 Nm 44 in lbs starting from...

Page 739: ...dles A pillar screw Right upper B pillar trim Engage front door weatherstrip to headliner 7 Ensure sunroof adjustment Refer to Sunroof Glass Adjustment GLASS PANEL REMOVAL 1 Position sunroof sunshade...

Page 740: ...ss attaching screws adjust as necessary SUNSHADE REMOVAL 1 Open sunroof glass panel to the vent position 2 Through the glass panel opening disengage the two rear slide blocks of sunshade from sunshade...

Page 741: ...roof flange 5 Rotate corner piece to a vertical position and pull it up through hole in the sunshade guide 6 Repeat for other corner piece INSTALLATION 1 Hold corner piece vertically and push tab dow...

Page 742: ...___________________________________________________________ ______________________________________________________________________________________ _____________________________________________________...

Page 743: ...DaimlerChrysler International Operations Attn Publications Dept CIMS 486 02 70 800 Chrysler Drive Auburn Hills MI 48326 2757 ProCarManuals com...

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