2001 dodge neon service repair manual

GROUP TAB LOCATOR
INs Introduction
0s Lubrication & Maintenance
5s Brakes
6s Clutch
7s Cooling
8Ns Power Systems
8Os Restraints
8W Wiring
9s Engine
21s Transaxle
23s Body
Service Manual Comment Forms (Rear of Manual)

INTRODUCTION
TABLE OF CONTENTS
page page
E-MARK LABEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TORQUE REFERENCES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E-MARK LABEL
DESCRIPTION - E-MARK LABEL
An E-mark Label (Fig. 1) is located on the rear
shut face of the driver’s door. The label contains the
following information:
• Date of Manufacture
• Month-Day-Hour (MDH)
• Vehicle Identification Number (VIN)
• Country Codes
• Regulation Number
• Regulation Amendment Number
• 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 left A-pillar
on left-hand-drive and right-hand-drive vehicles (Fig.
2) (Fig. 3). The VIN consists of 17 characters in a
combination of letters and numbers that provide spe-
cific information about the vehicle. Refer to the VIN
Decoding Information Table to interpret VIN code.
Fig. 1 E-Mark Label
1 - Country Code
2 - Regulation Number
3 - Approval Number
4 - Amendment Number
Fig. 2 VIN Plate Location – R.H.D.
PL INTRODUCTION 1s
2001 NEON

VIN CHECK DIGIT
To protect the consumer from theft and possible
fraud the manufacturer is required to include a check
digit at the ninth position of the VIN. The check digit
is used by the manufacturer and government agen-
cies to verify the authenticity of the vehicle and offi-
cial documentation. The formula to use the check
digit is not released to the general public.
VIN DECODING INFORMATION
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of origin 1 = Built in the U.S. by DaimlserChrysler 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 = DD5 5-Speed Manual Transmission
A = 3-Speed Automatic Transmission
7 Body Style 7 = 4 Door Pillared Hardtop
8 Engine C = 2.0L 4 Cyl. 16V SOHC
A = 1.8L 4 Cyl. 16V SOHC
D = 1.9L 4 Cyl. Turbo Diesel
9 Check Digit See explanation in this section.
10 Model Year 1 = 2001
11 Assembly Plant D = Belvedere Assembly
12 Thru 17 Build Sequence 6 Digit number assigned by assembly plant
Fig. 3 V.I.N. Plate Location – L.H.D.
2s INTRODUCTION PL
VEHICLE IDENTIFICATION NUMBER (Continued)
2001 NEON

TORQUE REFERENCES
DESCRIPTION
Individual 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 INTRODUCTION 3s
2001 NEON

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
LUBRICATION & MAINTENANCE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FLUID TYPES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FLUID CAPACITIES
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 4
MAINTENANCE SCHEDULES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
LUBRICATION &
MAINTENANCE
DESCRIPTION
This 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 this information you may
be referred to another section of the Service
Manual. The “Refer to” is written differently
than in prior years.
FLUID TYPES
DESCRIPTION - ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene 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 from engine metal, in
the cylinder head area near the exhaust valves and
engine block. Then coolant carries the heat to the
radiator where the tube/fin radiator can transfer the
heat to the air.
The use of aluminum cylinder blocks, cylinder
heads, and water pumps requires special corrosion
protection. Mopart Antifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769), or the equiva-
lent ethylene glycol base coolant with organic corro-
sion inhibitors (called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% Ethylene Glycol and 50% distilled
water to obtain a freeze point of -37°C (-35°F). If it
loses color or becomes contaminated, drain, flush,
and replace with fresh properly mixed coolant solu-
tion.
CAUTION: MoparT Antifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Doing so
will reduce the corrosion protection and may result
in premature water pump seal failure. If non-HOAT
coolant is introduced into the cooling system in an
emergency, it should be replaced with the specified
coolant as soon as possible.
DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID
NOTE: Refer to the maintenance schedules for the
recommended maintenance (fluid/filter change)
intervals for this transaxle.
PL LUBRICATION & MAINTENANCE 0s - 1
2001 NEON

NOTE: For fluid level checking procedures, (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/FLUID - STANDARD PROCEDURE).
NOTE: The 31TH transaxle has a common transmis-
sion and differential sump. Filling the transaxle
accommodates the differential as well.
TRANSMISSION FLUID
Mopart ATF+4 (Automatic Transmission Fluid-
Type 9602) is required in this transaxle. Substitute
fluids can induce torque converter clutch shudder.
Mopart ATF+4 (Automatic Transmission Fluid-
Type 9602) when new is red in color. The ATF is dyed
red so it can be identified from other fluids used in
the vehicle such as engine oil or antifreeze. The red
color is not permanent and is not an indicator of fluid
condition. As the vehicle is driven, the ATF will begin
to look darker in color and may eventually become
brown. This is normal. A dark brown/black fluid
accompanied with a burnt odor and/or deterioration
in shift quality may indicate fluid deterioration or
transmission component failure.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various “special” additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additives must not be used. The use of trans-
mission “sealers” should also be avoided, since they
may adversely affect the integrity of transmission
seals.
DESCRIPTION - GEAR LUBRICATION RATINGS
SAE ratings also apply to multiple grade gear
lubricants. In addition, API classification defines the
lubricants usage.
DESCRIPTION - FUEL REQUIREMENTS
Your engine is designed to meet all emissions reg-
ulations and provide excellent fuel economy and per-
formance when using high quality unleaded gasoline
having an octane rating of 87. The use of premium
gasoline is not recommended. The use of premium
gasoline will provide no benefit over high quality reg-
ular gasoline, and in some circumstances may result
in poorer performance.
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 result-
ing from operation with a heavy spark knock may
not be covered by the new vehicle warranty.
Poor quality gasoline can cause problems such as
hard starting, stalling and hesitations. If you experi-
ence these symptoms, try another brand of gasoline
before considering service for the vehicle.
Over 40 auto manufacturers world-wide have
issued and endorsed consistent gasoline specifications
(the Worldwide Fuel Charter, WWFC) to define fuel
properties necessary to deliver enhanced emissions,
performance and durability for your vehicle. We rec-
ommend the use of gasolines that meet the WWFC
specifications if they are available.
REFORMULATED GASOLINE
Many areas of the country require the use of
cleaner burning gasoline referred to as “reformulat-
ed” gasoline. Reformulated gasoline contain oxygen-
ates, and are specifically blended to reduce vehicle
emissions and improve air quality.
We strongly support the use of reformulated gaso-
line. Properly blended reformulated gasoline will pro-
vide excellent performance and durability for the
engine and fuel system components.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
oxygenates such as 10% ethanol, MTBE, and ETBE.
Oxygenates are required in some areas of the country
during the winter months to reduce carbon monoxide
emissions. Fuels blended with these oxygenates may
be used in your vehicle.
CAUTION: DO NOT use gasoline containing METH-
ANOL. Gasoline containing methanol may damage
critical fuel system components.
MMT IN GASOLINE
MMT is a manganese-containing metallic additive
that is blended into some gasoline to increase octane.
Gasoline blended with MMT provide no performance
advantage beyond gasoline of the same octane num-
ber without MMT. Gasoline blended with MMT
reduce spark plug life and reduce emission system
performance in some vehicles. We recommend that
gasolines free of MMT be used in your vehicle. The
MMT content of gasoline may not be indicated on the
gasoline pump; therefore, you should ask your gaso-
line retailer whether or not his/her gasoline contains
MMT.
It is even more important to look for gasoline with-
out MMT in Canada because MMT can be used at
0s - 2 LUBRICATION & MAINTENANCE PL
FLUID TYPES (Continued)
2001 NEON

levels higher than allowed in the United States.
MMT is prohibited in Federal and California refor-
mulated gasoline.
SULFUR IN GASOLINE
If you live in the northeast United States, your
vehicle may have been designed to meet California
low emission standards with Cleaner-Burning Cali-
fornia reformulated gasoline with low sulfur. If such
fuels are not available in states adopting California
emission standards, your vehicles will operate satis-
factorily on fuels meeting federal specifications, but
emission control system performance may be
adversely affected. Gasoline sold outside of California
is permitted to have higher sulfur levels which may
affect the performance of the vehicle’s catalytic con-
verter. This may cause the Malfunction Indicator
Lamp (MIL), Check Engine or Service Engine Soon
light to illuminate. We recommend that you try a dif-
ferent brand of unleaded gasoline having lower sulfur
to determine if the problem is fuel related prior to
returning your vehicle to an authorized dealer for
service.
CAUTION: If the Malfunction Indicator Lamp (MIL),
Check Engine or Service Engine Soon light is flash-
ing, immediate service is required; see on-board
diagnostics system section.
MATERIALS ADDED TO FUEL
All gasoline sold in the United States and Canada
are required to contain effective detergent additives.
Use of additional detergents or other additives is not
needed under normal conditions.
FUEL SYSTEM CAUTIONS
CAUTION: Follow these guidelines to maintain your
vehicle’s performance:
• The use of leaded gas is prohibited by Federal
law. Using leaded gasoline can impair engine perfor-
mance, damage the emission control system, and
could 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 smoke, your engine may be out of tune or
malfunctioning and may require immediate service.
Contact your dealer for service assistance.
• When pulling a heavy load or driving a fully
loaded vehicle when the humidity is low and the tem-
perature is high, use a premium unleaded fuel to
help prevent spark knock. If spark knock persists,
lighten the load, or engine piston damage may result.
• The use of fuel additives which are now being
sold as octane enhancers is not recommended. Most
of these products contain high concentrations of
methanol. Fuel system damage or vehicle perfor-
mance problems resulting from the use of such fuels
or additives is not the responsibility of
DaimlerChrysler Corporation and may not be covered
under the new vehicle warranty.
NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
DESCRIPTION - ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi-
fied. MOPARt provides engine oils, meeting Material
Standard MS-6395, that conform to this service
grade.
2001 NEON

SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only engine oils with multi-
ple viscosities such as 5W-30 or 10W-30. These are
specified with a dual SAE viscosity grade which indi-
cates the cold-to-hot temperature viscosity range.
Select an engine oil that is best suited to your par-
ticular temperature range and variation (Fig. 1).
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. The designation of ENERGY CON-
SERVING is located on the label of an engine oil con-
tainer.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 2).
This symbol on the front of an oil container means
that the oil has been certified by the American Petro-
leum Institute (API) to meet all the lubrication
requirements specified by DaimlerChrysler.
OPERATION - ENGINE COOLANT
The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves and
engine block. Then coolant carries the 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 GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
FLUID CAPACITIES
SPECIFICATIONS
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
Fuel Tank 47.5 L (12.5 gal.)
Engine Oil* 4.3 L (4.5 qts.)
Cooling System** 6.2 L (6.5 qts.)
Automatic Transaxle -
Estimated Service Fill
3.8 L (4.0 qts.)
Automatic Transaxle -
Overhaul Fill Capacity
with Torque Converter
Empty
8.1 L (8.6 qts.)
Manual Transaxle - NV
T350
2.4–2.7 L (2.5-2.8 qts.)
*(includes filter)
**(includes heater and recovery/reserve bottle)
Fig. 1 TEMPERATURE/ENGINE OIL VISCOSITY
Fig. 2 Engine Oil Container Standard Notations
2001 NEON

MAINTENANCE SCHEDULES
DESCRIPTION
There are two maintenance schedules that show
proper service for your vehicle.
First is Schedule – A. It lists all the scheduled
maintenance to be performed under “normal” operat-
ing conditions.
Second is Schedule – B. It is a schedule for vehi-
cles that are operated under the following conditions:
• Frequent short trip driving less than 5 miles (8
km)
• Frequent driving in dusty conditions
• Extensive idling
• More than 50% of the driving is at sustained
high speeds during hot weather, above 90° F (32° C)
UNSCHEDULED INSPECTION
At Each Stop For Fuel
• Check engine oil level and add as required.
• Check windshield washer solvent and add as
required.
Once A Month
• Check tire pressure and look for unusual wear
or damage.
• Inspect the battery and clean and tighten termi-
nals as required.
• Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission.
Add fluid as required.
• Check all lights and all other electrical items for
correct operation.
At Each Oil Change
• Inspect the exhaust system.
• Inspect brake hoses.
• Inspect the CV joints and front suspension com-
ponent boots and seals.
• Rotate the tires at each oil change interval
shown on Schedule – A (7,500 miles - 12 000 km) or
every other interval on Schedule – B (6,000 miles -
10 000 km).
• Check the engine coolant level, hoses, and
clamps.
If mileage is less than 7,500 miles (12 000 km)
yearly, replace the engine oil filter at each oil change.
EMISSION CONTROL SYSTEM MAINTENANCE
The scheduled emission maintenance listed in bold
type on the Maintenance Schedules, 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 provide the best vehicle
performance and reliability. More frequent mainte-
nance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.
FLUID FILL POINTS AND LUBRICATION
LOCATIONS
The fluid fill/check locations and lubrication loca-
tions are located in each applicable group.
SCHEDULE – A
7,500 Miles (12 000 km) or at 6 months
• Change the engine oil.
• Replace the engine oil filter.
• Inspect the front brake pads and rear brake lin-
ings.
• Inspect the tie rod ends and boot seals.
• Adjust the generator belt tension.
• Replace the engine air cleaner element (fil-
ter).
• Replace the engine spark plugs
ings.
• Inspect the tie rod ends and boots seals.
• Check the PCV valve and replace, if neces-
sary. Not required if previously changed.*
• Replace the drive belts.
2001 NEON

ter).
• Replace the ignition cables.
• Replace the spark plugs.
ings.
• Flush and replace engine coolant if 60 months
have been reashed before 100,000 miles (160 000
km).
• Check the PCV valve and replace, if neces-
sary. Not required if previously changed.*
ings.
ter).
• Replace the spark plugs.
100,000 Miles (160 000 km)
• Flush and replace the engine coolant if it was
not done at 60 months.
• Replace the engine timing belt.
*This maintenance is recommended by
DaimlerChrysler Corporation 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.
SCHEDULE – B
3,000 Miles (5 000 km)
6,000 Miles (10 000 km)
9,000 Miles (14 000 km)
ings.
12,000 Miles (19 000 km)
15,000 Miles (24 000 km)
• Inspect the engine air cleaner element (fil-
ter). Replace as necessary.*
18,000 Miles (29 000 km)
ings.
21,000 Miles (34 000 km)
24,000 Miles (38 000 km)
27,000 Miles (43 000 km)
ings.
30,000 Miles (48 000 km)
• Inspect the PCV valveand replace as neces-
sary.*
ter).
• Replace the spark plugs
MAINTENANCE SCHEDULES (Continued)
2001 NEON

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33,000 Miles (53 000 km)
36,000 Miles (58 000 km)
ings.
39,000 Miles (62 000 km)
42,000 Miles (67 000 km)
45,000 Miles (72 000 km)
ings.
ter). Replace as necessary.*
48,000 Miles (77 000 km)
• Change the automatic transaxle fluid and filter
and adjust the bands.
51,000 Miles (82 000 km)
54,000 Miles (86 000 km)
ings.
57,000 Miles (91 000 km)
60,000 Miles (96 000 km)
• Inspect the tie rod ends and boot seals.
• Inspect the PCV valveand replace if necessary.*
• Replace the drive belts.
ter).
• Replace the ignition cables
• Change the automatic transaxle fluid/filter and
adjust bands.
63,000 Miles (101 000 km)
66,000 Miles (106 000 km)
69,000 Miles (110 000 km)
72,000 Miles (115 000 km)
ings.
75,000 Miles (120 000 km)
ter) and replace as necessary.*
78,000 Miles (125 000 km)
81,000 Miles (130 000 km)
ings.
84,000 Miles (134 000 km)
87,000 Miles (139 000 km)
90,000 Miles (144 000 km)
• Inspect front brake pads and rear brake linings
• Check the PCV valve and replace if necessary.
Not required if previously changed.*
ter).
2001 NEON

93,000 Miles (149 000 km)
96,000 Miles (154 000 km)
• Change the automatic transaxle fluid and filter
and adjust the bands.
99,000 Miles (158 000 km)
ings.
102,000 Miles (163 000 km)
105,000 Miles (168 000 km)
• Replace the engine timing belt.
ter) and replace as necessary.*
* This maintenance is recommended by
DaimlerChrysler Corporation to the owner but is not
required to maintain the emissions warranty.
NOTE: Operating the vehicle more than 50% in
heavy traffic during hot weather, above 90° F (32°
C), using vehicle for police, taxi, limousine type
operation or trailer towing require the more fre-
quent transaxle service noted in Schedule – B. Per-
form these services if vehicle usually operate under
these conditions.
NOTE: Inspection and service should also be per-
formed anytime a malfunction is observed or sus-
pected. Retain all receipts.
2001 NEON

BRAKES
TABLE OF CONTENTS
page page
BRAKES-BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BRAKES-ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
BRAKES-BASE
TABLE OF CONTENTS
page page
BRAKES-BASE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 2
BASE BRAKE SYSTEM DIAGNOSIS
CHARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 5
BASE BRAKE BLEEDING. . . . . . . . . . . . . . . . . . 5
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE FLUID LEVEL SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HYDRAULIC/MECHANICAL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
BRAKE PADS/SHOES-FRONT
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BRAKE PADS/SHOES-REAR DISC
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DISC BRAKE CALIPERS-FRONT
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DISC BRAKE CALIPERS-REAR
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FLUID RESERVOIR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
MASTER CYLINDER-LHD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
PROPORTIONING VALVE. . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SHOES-PARKING BRAKE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CABLES-PARKING BRAKE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
LEVER-PARKING BRAKE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
BRAKES-BASE
DESCRIPTION
This 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 this information you may
be referred to another section of the Service
Manual. The refer to is written differently than
in prior years.
PL BRAKES 5s - 1
2001 NEON

DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM DIAGNOSIS CHARTS
NOTE: There are three diagnosis charts following
that cover the RED BRAKE WARNING INDICATOR
LAMP, BRAKE NOISE and OTHER BRAKE CONDI-
TIONS.
RED BRAKE WARNING INDICATOR LAMP
CONDITION POSSIBLE CAUSES CORRECTION
RED BRAKE WARNING
INDICATOR LAMP ON
1. Parking brake lever not fully
released.
1. Release parking brake lever.
2. Parking brake warning lamp
switch on parking brake lever.
2. Inspect and replace switch as necessary.
3. Brake fluid level low in reservoir. 3. Fill reservoir. Check entire system for
leaks. Repair or replace as required.
4. Brake fluid level switch. 4. Disconnect switch wiring connector. If
lamp goes out, replace switch.
5. Mechanical instrument cluster
(MIC) problem.
5. Refer to Chassis Diagnostic Procedures
manual.
6. ABS EBD malfunction. 6. Refer to ABS section and Chassis
Diagnostic Procedures manual.
BRAKE NOISE
DISC BRAKE CHIRP 1. 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. Broken or missing anti-rattle
spring clips on shoes.
1. Replace brake shoes.
2. Caliper guide pins loose. 2. Tighten guide pins.
DISC BRAKE SQUEAK AT
LOW SPEED (WHILE
APPLYING LIGHT BRAKE
PEDAL EFFORT)
1. Brake shoe linings. 1. Replace brake shoes.
DRUM BRAKE CHIRP 1. Lack of lubricant on brake shoe
support plate where shoes ride.
1. Lubricate shoe contact areas on brake
shoe support plates.
2. Wheel cylinder out of alignment. 2. Loosen wheel cylinder mounting bolts,
realign wheel cylinder with brake shoes and
tighten mounting bolts.
DRUM BRAKE CLUNK 1. Drum(s) have threaded machined
braking surface.
1. Reface or replace drake drums as
necessary.
DRUM BRAKE HOWL OR
MOAN
1. Lack of lubricant on brake shoe
support plate where shoes ride and
at the anchor.
1. Lubricate shoe contact areas on brake
shoe support plates and at the anchor.
2. Rear brake shoes. 2. Replace rear brake shoes.
5s - 2 BRAKES-BASE PL
BRAKES-BASE (Continued)
2001 NEON

DRUM BRAKE SCRAPING
OR WHIRRING
1. ABS wheel speed sensor or tone
wheel.
1. Inspect, correct or replace faulty
component(s).
SCRAPING (METAL-TO-
METAL).
1. Foreign object interference with
brakes.
1. Inspect brakes and remove foreign
object.
2. Brake shoes worn out. 2. Replace brake shoes. Inspect rotors and
drums. Reface or replace as necessary.
OTHER BRAKE CONDITIONS
BRAKES CHATTER 1. Rear brake drum out of round or
disc brake rotor has excessive
thickness variation.
1. Isolate condition as rear or front.
Reface or replace brake drums or
rotors as necessary.
BRAKES DRAG (FRONT
OR ALL)
1. Contaminated brake fluid. 1. Check for swollen seals. Replace all
system components containing rubber.
2. Binding caliper pins or bushings. 2. Replace pins and bushings
3. Binding master cylinder. 3. Replace master cylinder.
4. Binding brake pedal. 4. Replace brake pedal.
BRAKES DRAG (REAR
ONLY)
1. Parking brake cables binding or
froze up.
1. Check cable routing. Replace cables
as necessary.
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 section.
4. Obstruction inside the center
console preventing full return of the
parking brake cables.
4. Remove console and remove
obstruction.
BRAKES GRAB 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
Repair source of contamination.
2. Improper power brake booster
assist.
2. Refer to power brake booster in the
diagnosis and testing section.
EXCESSIVE PEDAL
EFFORT
1. Obstruction of brake pedal. 1. Inspect, remove or move obstruction.
2. Low power brake booster assist. 2. Refer to power brake booster in the
3. Glazed brake linings. 3. Reface or replace brake rotors as
necessary. Replace brake shoes.
4. Brake shoe lining transfer to brake
rotor.
4. Reface or replace brake rotors as
necessary. Replace brake shoes.
EXCESSIVE PEDAL
TRAVEL (VEHICLE STOPS
OK)
1. Air in brake lines. 1. Bleed brakes.
2. Rear drum brake auto-adjuster
malfunctioning.
2. Inspect and replace drum brake
components as necessary. Adjust rear
brakes.
PL BRAKES-BASE 5s - 3
2001 NEON

EXCESSIVE PEDAL
TRAVEL (PEDAL GOES
TO FLOOR - CAN’T SKID
WHEELS)
1. Power brake booster runout
(vacuum assist).
1. Check booster vacuum hose and
engine tune for adequate vacuum
supply. Refer to power brake booster in
the diagnosis and testing section.
EXCESSIVE PEDAL
TRAVEL (ONE FRONT
WHEEL LOCKS UP
DURING HARD BRAKING)
1. One of the two hydraulic circuits
to the front brakes is malfunctioning.
1. Inspect system for leaks. Check
master cylinder for internal malfunction.
PEDAL PULSATES/
SURGES DURING
BRAKING
1. Rear brake drum out of round or
disc brake rotor has excessive
thickness variation.
1. Isolate condition as rear or front.
Reface or replace brake drums or
rotors as necessary.
PEDAL IS SPONGY 1. Air in brake lines. 1. Bleed brakes.
2. Power brake booster runout
(vacuum assist).
2. Check booster vacuum hose and
engine tune for adequate vacuum
supply. Refer to power brake booster in
the diagnosis and testing section.
PREMATURE REAR
WHEEL LOCKUP
1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
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. Refer to the ABS section and
Chassis Diagnostic Procedures manual.
4. Improper power brake booster
assist.
4. Refer to power brake booster in the
STOP LAMPS STAY ON 1. Brake lamp switch out of
adjustment.
1. Adjust brake lamp switch.
2. Brake pedal binding. 2. Inspect and replace as necessary.
3. Obstruction in pedal linkage. 3. Remove obstruction.
4. Power Brake Booster not allowing
pedal to return completely.
4. Replace power brake booster.
VEHICLE PULLS TO
RIGHT OR LEFT ON
BRAKING
1. Frozen brake caliper piston. 1. Replace frozen piston or caliper.
Bleed brakes.
2. Contaminated brake shoe lining. 2. Inspect and clean, or replace shoes.
3. Pinched brake lines. 3. Replace pinched line.
4. Leaking piston seal. 4. Replace piston seal or brake caliper.
5. Suspension problem. 5. Refer to the Suspension group.
PARKING BRAKE -
EXCESSIVE HANDLE
TRAVEL
1. Rear brakes out of adjustment. 1. Adjust rear drum brake shoes, or
rear parking brake shoes on vehicles
with rear disc brakes.
5s - 4 BRAKES-BASE PL
2001 NEON

STANDARD PROCEDURE - BASE BRAKE
BLEEDING
NOTE: For bleeding the ABS hydraulic system, refer
to Antilock Brake System Bleeding in the Antilock
Brake System section.
CAUTION: Before removing the master cylinder cap,
wipe it clean to prevent dirt and other foreign mat-
ter from dropping into the master cylinder reservoir.
CAUTION: Use only MoparT brake fluid or an equiv-
alent from a fresh, tightly sealed container. Brake
fluid must conform to DOT 3 specifications.
Do not pump the brake pedal at any time while
having a bleeder screw open during the bleeding pro-
cess. This will only increase the amount of air in the
system and make additional bleeding necessary.
Do not allow the master cylinder reservoir to run
out of brake fluid while bleeding the system. An
empty reservoir will allow additional air into the
brake system. Check the fluid level frequently and
add fluid as needed.
The following wheel circuit sequence for bleeding
the brake hydraulic system should be used to ensure
adequate removal of all trapped air from the hydrau-
lic system.
• Left rear wheel
• Right front wheel
• Right rear wheel
• Left front wheel
MANUAL BLEEDING
NOTE: To bleed the brakes manually, the aid of a
helper will be required.
(1) Attach a clear plastic hose to the bleeder screw
and feed the hose into a clear jar containing enough
fresh brake fluid to submerge the end of the hose
(Fig. 1).
(2) Have a helper pump the brake pedal three or
four times and hold it in the down position.
(3) With the pedal in the down position, open the
bleeder screw at least 1 full turn.
(4) Once 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 (usually four or five
times).
(6) Bleed the remaining wheel circuits in the same
manner until all air is removed from the brake sys-
tem. Monitor the fluid level in the master cylinder
reservoir to make sure it does not go dry.
(7) Check the brake pedal travel. If pedal travel is
excessive or has not been improved, some air may
still be trapped in the system. Rebleed the brakes as
necessary.
(8) Test drive the vehicle to verify the brakes are
operating properly and pedal feel is correct.
PRESSURE BLEEDING
NOTE: Follow pressure bleeder manufacturer’s
instructions for use of pressure bleeding equip-
ment.
Following the same wheel circuit sequence as pre-
scribed for manual bleeding.
(1) Attach Adapter, Special Tool 6921, to the mas-
ter cylinder reservoir (Fig. 2).
(2) Attach Bleeder Tank, Special Tool C-3496-B, or
an equivalent, to the adapter on the master cylinder.
(3) Attach a clear plastic hose to the bleeder screw
and feed the hose into a clear jar containing enough
fresh brake fluid to submerge the end of the hose
(Fig. 1).
(4) Open the bleeder screw at least one full turn or
more to obtain a steady stream of brake fluid.
(5) After approximately 4–8 ounces of fluid have
been bled through the brake circuit and an air-free
flow is maintained in the clear plastic hose and jar,
close the bleeder screw.
(6) Repeat this procedure at all the remaining
bleeder screws.
Fig. 1 Proper Method for Purging Air From Brake
System (Typical)
1 - CLEAR HOSE
2 - BRAKE CALIPER
3 - BLEEDER SCREW
4 - CLEAN BRAKE FLUID
PL BRAKES-BASE 5s - 5
2001 NEON

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