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Chrysler Dodge Neon 1999 Service Repair Manual

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🏷️ 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...
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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
🏷️ 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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