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Chrysler Dodge Neon 1999 Service Repair Manual

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The 1999 Dodge Neon represents a significant entry in the compact car segment, known for its distinctive cab-forward design and agile handling, largely attributed to its multi-link rear suspension. Offering a balance of sporty styling and practicality, this vehicle was engineered by Chrysler for budget-conscious consumers and younger drivers. It was powered by efficient 2.0-liter inline-4 engines, available in both SOHC and DOHC configurations, paired with either a 5-speed manual or a 4-speed automatic transmission. The Neon's competitive advantage often lay in its spacious interior and aerodynamic profile, making it a notable competitor in its class during its production run. This comprehensive Factory Service Manual (FSM) is designed to be an authoritative resource for the 1999 Dodge Neon. It covers a wide array of vehicle maintenance and repair procedures, from routine service like oil changes and filter replacements to in-depth diagnostics and troubleshooting for all major systems. The manual details engine mechanicals, fuel and ignition systems, transmissions (manual and automatic), brakes, steering, suspension, and electrical components, including detailed wiring diagrams. It also provides guidance on HVAC systems, bodywork, and includes essential technical specifications, torque values, and information on special tools, empowering owners and technicians to effectively maintain and repair the vehicle. 🏷️ Basic Information Identification Make: Chrysler Model: Dodge Neon Year: 1999 Codes Platform Code: PL (Second Generation Neon) 👋 Introduction Market Position Segment: Compact Car Target Audience: Budget-conscious consumers, younger drivers, small families Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Ford Escort, Chevrolet Cavalier, Volkswagen Golf Competitive Advantage: Often offered more interior space and sporty styling for the price, agile handling Key Features Design: Distinctive cab-forward design, aerodynamic styling Powertrain Options: DOHC inline-4 engines, available manual and automatic transmissions Handling: Multi-link rear suspension (a standout feature for its class) 📋 Manual Details Coverage Areas Primary Coverage: Vehicle Maintenance and Repair Secondary Coverage: Diagnostics and Troubleshooting Page Count Estimated Pages: Approximately 1500-2000 (typical for comprehensive service manuals of this era) Manual Type Type: Factory Service Manual (FSM) Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, valve train, crankshaft, pistons, connecting rods, lubrication system, cooling system Engine Performance: Fuel system (injection, pumps, injectors), ignition system (coils, plugs, timing), exhaust system, emissions control (EVAP, EGR) Transmission Manual: Clutch system, gearbox, shift linkage, torque specifications, internal components Transmission Automatic: Torque converter, valve body, transmission control module (TCM), hydraulic circuits, fluid specifications, internal components Brakes: Front disc brakes, rear drum brakes, ABS system (if equipped), hydraulic lines, calipers, master cylinder, parking brake Steering: Power steering system, steering column, steering gear, tie rods, alignment specifications Suspension: Front struts, rear shock absorbers, control arms, ball joints, bushings, springs, alignment specifications Electrical Engine: Engine Control Module (ECM), sensors (MAF, O2, TPS, CMP, CKP), actuators, wiring diagrams Electrical Body: Lighting, power windows, power locks, interior electronics, comfort features, body control module (BCM) HVAC: Heating, ventilation, and air conditioning systems, refrigerant charging, component testing Body Exterior: Body panel removal and installation, door mechanisms, glass replacement, trim components Body Interior: Dashboard removal, seat removal, interior trim, carpeting Chassis: Frame and underbody components, mounting points Procedures Included Maintenance Routine: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement Troubleshooting Diagnostics: Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical testing, pressure testing Repair Engine: Engine rebuilds, head gasket replacement, timing belt replacement, component replacement (alternator, starter, water pump) Repair Transmission: Transmission rebuilds, clutch replacement, fluid and filter changes, seal replacement Repair Brakes: Brake pad/shoe replacement, rotor/drum resurfacing/replacement, brake fluid flush, ABS component replacement Repair Suspension Steering: Strut/shock replacement, control arm replacement, alignment procedures, power steering pump replacement Repair Electrical: Wiring harness repair, sensor replacement, module testing and replacement, battery and charging system service Body Repair: Panel alignment, door hinge adjustment, glass installation HVAC Repair: Refrigerant system evacuation and recharge, component replacement (compressor, condenser, evaporator) Torque Specifications: Comprehensive torque values for critical fasteners across all systems Special Tools: Identification and usage of specific Chrysler/Dodge special tools required for certain procedures Technical Depth Depth: Comprehensive (from basic maintenance to full engine/transmission rebuilds and advanced diagnostics) Diagnostic Methods: Detailed diagnostic flowcharts and procedures for identifying faults Wiring Diagrams: Complete electrical schematics for all vehicle systems 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text-based PDF (depending on scanning quality of original document) Printability: Printable (standard PDF feature) Print Quality Quality: Dependent on original source document scan quality, generally good for factory manuals Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code: SOHC: 2.0L (1996 cc) I4 (16-valve) - Part Number: 04856500 Engine Code DOHc: DOHC: 2.0L (1996 cc) I4 (16-valve) - Part Number: 04856510 Performance Sohc Horsepower Sohc: 132 hp @ 5600 rpm Torque Sohc: 130 lb-ft @ 4000 rpm Performance Dohc Horsepower DOHc:...
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Chrysler Dodge Neon 1999 Service Repair ManualChrysler Dodge Neon 1999 Service Repair ManualChrysler Dodge Neon 1999 Service Repair ManualChrysler Dodge Neon 1999 Service Repair Manual
The 1999 Dodge Neon represents a significant entry in the compact car segment, known for its distinctive cab-forward design and agile handling, largely attributed to its multi-link rear suspension. Offering a balance of sporty styling and practicality, this vehicle was engineered by Chrysler for budget-conscious consumers and younger drivers. It was powered by efficient 2.0-liter inline-4 engines, available in both SOHC and DOHC configurations, paired with either a 5-speed manual or a 4-speed automatic transmission. The Neon's competitive advantage often lay in its spacious interior and aerodynamic profile, making it a notable competitor in its class during its production run. This comprehensive Factory Service Manual (FSM) is designed to be an authoritative resource for the 1999 Dodge Neon. It covers a wide array of vehicle maintenance and repair procedures, from routine service like oil changes and filter replacements to in-depth diagnostics and troubleshooting for all major systems. The manual details engine mechanicals, fuel and ignition systems, transmissions (manual and automatic), brakes, steering, suspension, and electrical components, including detailed wiring diagrams. It also provides guidance on HVAC systems, bodywork, and includes essential technical specifications, torque values, and information on special tools, empowering owners and technicians to effectively maintain and repair the vehicle.
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Dodge Neon
Year:
1999
Codes
Platform Code:
PL (Second Generation Neon)
👋 Introduction
Market Position
Segment:
Compact Car
Target Audience:
Budget-conscious consumers, younger drivers, small families
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Ford Escort, Chevrolet Cavalier, Volkswagen Golf
Competitive Advantage:
Often offered more interior space and sporty styling for the price, agile handling
Key Features
Design:
Distinctive cab-forward design, aerodynamic styling
Powertrain Options:
DOHC inline-4 engines, available manual and automatic transmissions
Handling:
Multi-link rear suspension (a standout feature for its class)
📋 Manual Details
Coverage Areas
Primary Coverage:
Vehicle Maintenance and Repair
Secondary Coverage:
Diagnostics and Troubleshooting
Page Count
Estimated Pages:
Approximately 1500-2000 (typical for comprehensive service manuals of this era)
Manual Type
Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, valve train, crankshaft, pistons, connecting rods, lubrication system, cooling system
Engine Performance:
Fuel system (injection, pumps, injectors), ignition system (coils, plugs, timing), exhaust system, emissions control (EVAP, EGR)
Transmission Manual:
Clutch system, gearbox, shift linkage, torque specifications, internal components
Transmission Automatic:
Torque converter, valve body, transmission control module (TCM), hydraulic circuits, fluid specifications, internal components
Brakes:
Front disc brakes, rear drum brakes, ABS system (if equipped), hydraulic lines, calipers, master cylinder, parking brake
Steering:
Power steering system, steering column, steering gear, tie rods, alignment specifications
Suspension:
Front struts, rear shock absorbers, control arms, ball joints, bushings, springs, alignment specifications
Electrical Engine:
Engine Control Module (ECM), sensors (MAF, O2, TPS, CMP, CKP), actuators, wiring diagrams
Electrical Body:
Lighting, power windows, power locks, interior electronics, comfort features, body control module (BCM)
HVAC:
Heating, ventilation, and air conditioning systems, refrigerant charging, component testing
Body Exterior:
Body panel removal and installation, door mechanisms, glass replacement, trim components
Body Interior:
Dashboard removal, seat removal, interior trim, carpeting
Chassis:
Frame and underbody components, mounting points
Procedures Included
Maintenance Routine:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement
Troubleshooting Diagnostics:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical testing, pressure testing
Repair Engine:
Engine rebuilds, head gasket replacement, timing belt replacement, component replacement (alternator, starter, water pump)
Repair Transmission:
Transmission rebuilds, clutch replacement, fluid and filter changes, seal replacement
Repair Brakes:
Brake pad/shoe replacement, rotor/drum resurfacing/replacement, brake fluid flush, ABS component replacement
Repair Suspension Steering:
Strut/shock replacement, control arm replacement, alignment procedures, power steering pump replacement
Repair Electrical:
Wiring harness repair, sensor replacement, module testing and replacement, battery and charging system service
Body Repair:
Panel alignment, door hinge adjustment, glass installation
HVAC Repair:
Refrigerant system evacuation and recharge, component replacement (compressor, condenser, evaporator)
Torque Specifications:
Comprehensive torque values for critical fasteners across all systems
Special Tools:
Identification and usage of specific Chrysler/Dodge special tools required for certain procedures
Technical Depth
Depth:
Comprehensive (from basic maintenance to full engine/transmission rebuilds and advanced diagnostics)
Diagnostic Methods:
Detailed diagnostic flowcharts and procedures for identifying faults
Wiring Diagrams:
Complete electrical schematics for all vehicle systems
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely searchable text-based PDF (depending on scanning quality of original document)
Printability:
Printable (standard PDF feature)
Print Quality
Quality:
Dependent on original source document scan quality, generally good for factory manuals
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
SOHC: 2.0L (1996 cc) I4 (16-valve) - Part Number: 04856500
Engine Code DOHc:
DOHC: 2.0L (1996 cc) I4 (16-valve) - Part Number: 04856510
Performance Sohc
Horsepower Sohc:
132 hp @ 5600 rpm
Torque Sohc:
130 lb-ft @ 4000 rpm
Performance Dohc
Horsepower DOHc:
150 hp @ 6400 rpm (Standard for SE/ES models)
Torque DOHc:
135 lb-ft @ 4800 rpm
Fuel System
Induction Type:
Electronic Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Regular (87 Octane) - Minimum
Engine Management
ECU Type:
Chrysler 'J' platform engine controller
🔧 Transmission
Standard Transmission
Type Std:
5-Speed Manual (Getrag G360-based)
Optional Transmission
Type Opt:
4-Speed Automatic (Chrysler 30/41TE)
Features
Fluid Type Auto:
ATF+4 (Automatic Transmission Fluid Type 9602)
Fluid Capacity Auto:
Approximately 9.0 quarts (8.5 L) for complete refill
Fluid Type Manual:
GL-3 or GL-4 SAE 75W-90 Gear Oil
Clutch Type:
Dry single plate with diaphragm spring
📐 Dimensions
Exterior
Length:
170.5 inches (4331 mm)
Width:
67.5 inches (1715 mm)
Height:
53.8 inches (1367 mm)
Wheelbase:
104.0 inches (2642 mm)
Track Width Front:
57.7 inches (1466 mm)
Track Width Rear:
57.9 inches (1471 mm)
Ground Clearance:
Approximately 5.0 inches (127 mm)
Weights
Curb Weight Base:
Approximately 2700 lbs (1225 kg)
Gross Vehicle Weight Rating Gvwr:
Approximately 3700 lbs (1678 kg)
Cargo
Trunk Volume:
Approximately 13.0 cubic feet (368 L)
🛡️ Safety Features
Ratings
NHTSA Driver Front Impact:
4/5 stars (Driver: Good, Passenger: Excellent)
NHTSA Passenger Front Impact:
5/5 stars (Passenger: Excellent)
IIHS Side Impact:
Acceptable (depends on specific trim and safety equipment)
Active Features
ABS:
Optional (Anti-lock Braking System)
Traction Control:
Rarely equipped on 1999 models
Passive Features
Airbags Front:
Driver and Passenger airbags (standard on most trims)
Seatbelts:
Front 3-point, rear 3-point (outboard), lap belt (center)
Child Seat Anchors:
LATCH system not present on this generation
💡 Technology Features
Infotainment
Head Unit:
Factory AM/FM/Cassette or optional CD player
Speakers:
Standard 4-speaker system, optional 6-speaker system
Driver Assistance
Cruise Control:
Optional
Keyless Entry:
Optional
Connectivity
Bluetooth:
Not available
Aux Input:
Not available
🔧 Maintenance
Service Intervals Oil
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first (with synthetic blend or full synthetic oil)
Oil Filter Replacement:
Replace with every oil change
Service Intervals Filters
Engine Air Filter:
Inspect every 7,500 miles, replace as needed (typically every 15,000-30,000 miles)
Cabin Air Filter:
Not typically equipped on 1999 models
Service Intervals Fluids
Coolant Flush:
Every 100,000 miles (160,000 km) or 5 years
Brake Fluid Flush:
Every 30,000 miles (48,000 km) or 2 years
Power Steering Fluid:
Check level regularly, replace fluid as needed (per manual recommendations)
Fluid Specifications
Engine Oil Type:
API Certified SAE 5W-30 (preferred), or SAE 10W-30
Engine Oil Capacity:
4.5 US quarts (4.3 L) with filter change
Coolant Type:
Mopar Antifreeze/Coolant (or equivalent HOAT) - 50/50 mix with distilled water
Coolant Capacity:
Approximately 7.0 US quarts (6.6 L)
Brake Fluid Type:
DOT 3
Known Issues
Engine Common:
Head gasket leaks (especially earlier models), oil filter housing leaks, noisy lifters
Transmission Common:
Automatic transmission solenoid failures, clutch wear (manual), synchro wear (manual)
Suspension Common:
Worn control arm bushings, failing front struts, rear shock absorber leaks
Electrical Common:
Power window motor failures, HVAC blower motor issues, intermittent sensor faults
Exhaust Common:
Catalytic converter failure, exhaust manifold cracks
📚 Vehicle History
Brand Heritage
Brand Focus:
Chrysler Corporation (Dodge division) focused on value, performance, and distinctive styling
Model Evolution
Generation:
Second Generation Neon (1995-1999)
Styling Changes Vs Previous:
Smoother, more aerodynamic lines; improved interior quality; updated platform
Production
Production Start Year:
1995
Production End Year:
2005 (for Neon platform, but this manual is for 1999 model year)
Manufacturing Locations:
Belvidere, Illinois, USA; Toluca, Mexico
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
Named to Car and Driver's 10Best list in 1995 (first generation, but established the Neon's reputation)
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