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Chrysler Neon 2000 Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Neon Year: 2000 Codes Chassis Code: PL 👋 Introduction Market Position Market Segment: Compact car, aimed at affordability and fuel efficiency, popular with younger drivers and first-time car buyers. Competitive Analysis Competitors: Ford Focus, Chevrolet Cavalier, Honda Civic, Toyota Corolla, Nissan Sentra. Key Features Design Philosophy: Aerodynamic styling, spacious interior for its class, focus on value for money. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service and repair for all major vehicle systems. Page Count Page Count: Approximately 1500+ Manual Type Manual Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: Digital (PDF) - Searchable, Printable 📖 Manual Coverage Systems Covered Engine: 2.0L SOHC and DOHC (Mitsubishi 4G93/4G94), diagnostic procedures, component testing, timing belt replacement, cooling system, lubrication system. Transmission: Manual (Getrag 283/NV1500) and Automatic (Chrysler A604/41TE), torque converter, clutch service, hydraulic control, shift control, diagnostics, fluid specifications. Brakes: Front disc, rear drum/disc options, ABS (Anti-lock Braking System) diagnostics and repair, hydraulic components, parking brake. Suspension: Front MacPherson strut, rear torsion beam axle, steering system (power steering pump, rack and pinion), wheel alignment specifications. Electrical: Complete wiring diagrams for all circuits, fuses, relays, lighting system, charging system, starting system, instrument cluster, power accessories, body control modules. HVAC: Air conditioning system refrigerant handling, compressor, condenser, evaporator, heater core, climate control module. Body: Exterior body panels, doors, hood, trunk, glass, bumpers, interior trim, seat removal, sound deadening. Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections. Repair: Engine component replacement, transmission overhaul, brake caliper replacement, suspension bushing replacement, starter motor replacement, alternator replacement. Diagnostics: Troubleshooting guides based on symptoms, diagnostic trouble codes (DTCs) and their meanings, component testing procedures, electrical circuit tracing. Troubleshooting: Step-by-step diagnostic trees for common and uncommon issues across all systems. Technical Depth Depth: Expert level: includes complete engine and transmission rebuild procedures, detailed electrical schematics, and advanced diagnostic techniques. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution scans of original factory documentation, ensuring clarity of diagrams and text. Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: 4G93 (SOHC) / 4G94 (DOHC) Displacement: 1997 cc (2.0 Liters) Performance Horsepower Sohc: 116 hp @ 5500 RPM (approx.) Torque Sohc: 130 lb-ft @ 4000 RPM (approx.) Horsepower DOHc: 132 hp @ 5500 RPM (approx.) Torque DOHc: 130 lb-ft @ 4400 RPM (approx.) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Multi-port Recommended Fuel: 87 Octane Unleaded Gasoline Technical Details Bore X Stroke: 81.0 mm x 95.0 mm Compression Ratio: 9.4:1 (SOHC) / 10.0:1 (DOHC) Engine Management System: Chrysler SBEC (Single Board Engine Controller) or equivalent, with OBD-II diagnostics. 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission (Getrag 283 / NV1500) Optional Transmission Type: 4-speed Automatic Transmission (Chrysler A604 / 41TE) Features Automatic Features: Electronically controlled, overdrive, torque converter lock-up. Fluid Specs Manual Fluid Type: API GL-4 SAE 75W-90 Gear Oil Automatic Fluid Type: ATF+4 (Chrysler MS-9602) 📐 Dimensions Exterior Length: 174.4 inches (4430 mm) Width: 67.4 inches (1712 mm) Height: 55.1 inches (1400 mm) Wheelbase: 104.0 inches (2642 mm) Interior Passenger Volume: 95.4 cubic feet (2701 L) Cargo Trunk Volume: 13.1 cubic feet (371 L) Weights Curb Weight: 2650 - 2850 lbs (1202 - 1293 kg) depending on trim and options. Gross Vehicle Weight Rating: 3700 lbs (1678 kg) (approx.) 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: 4 stars (for comparable models in that era) NHTSA Frontal Impact Passenger: 4 stars (for comparable models in that era) Active Features ABS: Optional on most trims, standard on some higher trims. Passive Features Airbags: Driver and front passenger airbags standard. Seatbelts: 3-point front and rear seat belts, front pretensioners. 💡 Technology Features Infotainment Audio System: AM/FM stereo with cassette player, optional CD player. Speaker configurations varied by trim level. Driver Assistance Cruise Control: Available on most trims. Connectivity OBD Standard: On-Board Diagnostics II (OBD-II) compliant. 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles (12,000 km) or 6 months, whichever comes first. Air Filter Replacement: Every 15,000 miles (24,000 km) or as needed based on driving conditions. Spark Plug Replacement: Every 100,000 miles (160,000 km) with original equipment (platinum or iridium plugs). Timing Belt Replacement: Every 90,000 - 100,000 miles (145,000 - 160,000 km) for SOHC and DOHC engines. Critical for preventing catastrophic engine damage. Fluid Specifications Coolant Type: Chrysler HOAT (Hybrid Organic Acid Technology) Pink Coolant (MS-9769) or equivalent. Power Steering Fluid: ATF+4 (Chrysler MS-9602) or equivalent. Brake Fluid Type: DOT 3 Known Issues Common Problems: Oil leaks (valve cover gasket, oil pan gasket), AC system leaks, suspension wear (bushings, ball joints), intermittent electrical issues, transmission solenoid failures (automatic). Timing Belt Failure Consequences: Interference engine design; belt failure will...
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Chrysler Neon 2000 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Neon
Year:
2000
Codes
Chassis Code:
PL
👋 Introduction
Market Position
Market Segment:
Compact car, aimed at affordability and fuel efficiency, popular with younger drivers and first-time car buyers.
Competitive Analysis
Competitors:
Ford Focus, Chevrolet Cavalier, Honda Civic, Toyota Corolla, Nissan Sentra.
Key Features
Design Philosophy:
Aerodynamic styling, spacious interior for its class, focus on value for money.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service and repair for all major vehicle systems.
Page Count
Page Count:
Approximately 1500+
Manual Type
Manual Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF) - Searchable, Printable
📖 Manual Coverage
Systems Covered
Engine:
2.0L SOHC and DOHC (Mitsubishi 4G93/4G94), diagnostic procedures, component testing, timing belt replacement, cooling system, lubrication system.
Transmission:
Manual (Getrag 283/NV1500) and Automatic (Chrysler A604/41TE), torque converter, clutch service, hydraulic control, shift control, diagnostics, fluid specifications.
Brakes:
Front disc, rear drum/disc options, ABS (Anti-lock Braking System) diagnostics and repair, hydraulic components, parking brake.
Suspension:
Front MacPherson strut, rear torsion beam axle, steering system (power steering pump, rack and pinion), wheel alignment specifications.
Electrical:
Complete wiring diagrams for all circuits, fuses, relays, lighting system, charging system, starting system, instrument cluster, power accessories, body control modules.
HVAC:
Air conditioning system refrigerant handling, compressor, condenser, evaporator, heater core, climate control module.
Body:
Exterior body panels, doors, hood, trunk, glass, bumpers, interior trim, seat removal, sound deadening.
Procedures Included
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections.
Repair:
Engine component replacement, transmission overhaul, brake caliper replacement, suspension bushing replacement, starter motor replacement, alternator replacement.
Diagnostics:
Troubleshooting guides based on symptoms, diagnostic trouble codes (DTCs) and their meanings, component testing procedures, electrical circuit tracing.
Troubleshooting:
Step-by-step diagnostic trees for common and uncommon issues across all systems.
Technical Depth
Depth:
Expert level: includes complete engine and transmission rebuild procedures, detailed electrical schematics, and advanced diagnostic techniques.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution scans of original factory documentation, ensuring clarity of diagrams and text.
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G93 (SOHC) / 4G94 (DOHC)
Displacement:
1997 cc (2.0 Liters)
Performance
Horsepower Sohc:
116 hp @ 5500 RPM (approx.)
Torque Sohc:
130 lb-ft @ 4000 RPM (approx.)
Horsepower DOHc:
132 hp @ 5500 RPM (approx.)
Torque DOHc:
130 lb-ft @ 4400 RPM (approx.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - Multi-port
Recommended Fuel:
87 Octane Unleaded Gasoline
Technical Details
Bore X Stroke:
81.0 mm x 95.0 mm
Compression Ratio:
9.4:1 (SOHC) / 10.0:1 (DOHC)
Engine Management System:
Chrysler SBEC (Single Board Engine Controller) or equivalent, with OBD-II diagnostics.
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission (Getrag 283 / NV1500)
Optional
Transmission Type:
4-speed Automatic Transmission (Chrysler A604 / 41TE)
Features
Automatic Features:
Electronically controlled, overdrive, torque converter lock-up.
Fluid Specs
Manual Fluid Type:
API GL-4 SAE 75W-90 Gear Oil
Automatic Fluid Type:
ATF+4 (Chrysler MS-9602)
📐 Dimensions
Exterior
Length:
174.4 inches (4430 mm)
Width:
67.4 inches (1712 mm)
Height:
55.1 inches (1400 mm)
Wheelbase:
104.0 inches (2642 mm)
Interior
Passenger Volume:
95.4 cubic feet (2701 L)
Cargo
Trunk Volume:
13.1 cubic feet (371 L)
Weights
Curb Weight:
2650 - 2850 lbs (1202 - 1293 kg) depending on trim and options.
Gross Vehicle Weight Rating:
3700 lbs (1678 kg) (approx.)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
4 stars (for comparable models in that era)
NHTSA Frontal Impact Passenger:
4 stars (for comparable models in that era)
Active Features
ABS:
Optional on most trims, standard on some higher trims.
Passive Features
Airbags:
Driver and front passenger airbags standard.
Seatbelts:
3-point front and rear seat belts, front pretensioners.
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with cassette player, optional CD player. Speaker configurations varied by trim level.
Driver Assistance
Cruise Control:
Available on most trims.
Connectivity
OBD Standard:
On-Board Diagnostics II (OBD-II) compliant.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or as needed based on driving conditions.
Spark Plug Replacement:
Every 100,000 miles (160,000 km) with original equipment (platinum or iridium plugs).
Timing Belt Replacement:
Every 90,000 - 100,000 miles (145,000 - 160,000 km) for SOHC and DOHC engines. Critical for preventing catastrophic engine damage.
Fluid Specifications
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) Pink Coolant (MS-9769) or equivalent.
Power Steering Fluid:
ATF+4 (Chrysler MS-9602) or equivalent.
Brake Fluid Type:
DOT 3
Known Issues
Common Problems:
Oil leaks (valve cover gasket, oil pan gasket), AC system leaks, suspension wear (bushings, ball joints), intermittent electrical issues, transmission solenoid failures (automatic).
Timing Belt Failure Consequences:
Interference engine design; belt failure will cause piston-to-valve contact leading to severe internal engine damage.
📚 Vehicle History
Brand Heritage
Parent Company:
Chrysler Corporation (later DaimlerChrysler)
Model Evolution
Generation 1 Start:
1995
Generation 1 End:
1999
Generation 2 Start:
2000
Generation 2 End:
2006
Production
Manufacturing Location:
Belvidere, Illinois, USA
Significance:
Chrysler's first truly global car, designed with European market influence.
🏆 Awards & Recognition
Recognitions
Year Of Recognition:
N/A (No specific major awards for the 2000 model year are widely documented; known for its value proposition).
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