Chrysler Neon 1999 Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Neon Year: 1999 Codes Platform Code: PL 👋 Introduction Market Position Segment: Compact car Target Audience: Budget-conscious buyers, first-time car owners, DIY enthusiasts, automotive repair shops. Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier, Mitsubishi Eclipse. Distinguishing Features: Aggressive styling (for its era), surprisingly spacious interior for its size, availability of spirited performance variants (ACR/R/T). Key Features Design Philosophy: Compact, aerodynamic, driver-focused interior, emphasis on value and performance. Body Styles: 2-door coupe, 4-door sedan. 📋 Manual Details Coverage Areas Primary Coverage: 1999 Chrysler Neon (all trims and engines) Secondary Coverage: Related models using shared components or platforms Page Count Estimated Pages: Approximately 1500-2000 Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (PDF, e-book) 📖 Manual Coverage Systems Covered Engine Mechanical: 2.0L SOHC (16-valve), 2.0L DOHC (16-valve - ACR/R/T models), disassembly, inspection, reassembly, timing, seals, gaskets, pistons, rings, bearings, cylinder head, valve train, crankshaft, camshafts. Engine Performance: Fuel injection (MPI), ignition system, emissions control, cooling system, lubrication system, engine mounts. Transmission Manual: 5-speed manual transmission (Getrag-sourced), clutch system, gear shifting mechanisms, internal components, fluid specifications. Transmission Automatic: 3-speed automatic transmission (Chrysler A500/42LE family), torque converter, valve body, planetary gears, hydraulic system, fluid specifications, cooling. Brakes: Front disc brakes (Vented), rear drum brakes, ABS (Antilock Braking System) diagnosis and repair, brake fluid specifications, hydraulic lines, parking brake. Suspension: Front MacPherson struts, rear independent multi-link suspension, shock absorbers, springs, bushings, alignment specifications, wheel bearing replacement. Steering: Power steering system (rack and pinion), hydraulic pump, steering gear, tie rod ends, steering column, universal joints. Electrical System: 12V battery system, charging system (alternator), starting system (starter motor), fuses, relays, wiring diagrams, lighting system, instrumentation, power windows, power locks, horn. Body And Interior: Body panel repair, door mechanisms, glass replacement, interior trim removal, seat removal, dashboard components, HVAC system (heater, A/C), body sealing. Diagnostics And Troubleshooting: OBD-II diagnostic trouble codes (DTCs), diagnostic procedures for all major systems, component testing, symptom-based troubleshooting guides. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, belt inspection/replacement, air filter replacement. Engine Repair: Head gasket replacement, timing belt/chain service, piston and ring replacement, bearing replacement, oil seal replacement, complete engine overhaul. Transmission Service: Clutch replacement, transmission fluid and filter changes, internal transmission repairs (manual and automatic), torque converter replacement. Brake Service: Brake pad/shoe replacement, rotor/drum replacement, caliper rebuild, ABS sensor replacement, brake line repair/replacement. Suspension And Steering Repair: Strut replacement, ball joint replacement, tie rod end replacement, power steering pump replacement, wheel alignment adjustment. Electrical Diagnosis And Repair: Starter/alternator testing, wiring harness repair, component testing (sensors, actuators), diagnostic tool usage, ECU troubleshooting. Bodywork And Trim: Door panel removal, interior trim replacement, glass installation, bumper repair, panel alignment. HVAC Service: Evaporator/condenser replacement, blower motor replacement, refrigerant handling (with proper certifications), cabin air filter replacement. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to full engine/transmission rebuilds and complex electrical diagnostics. Diagnostic Focus: Detailed diagnostic flowcharts, symptom analysis, and specific troubleshooting procedures for common and uncommon faults. Repair Instructions: Step-by-step repair instructions with torque specifications, special tool requirements, and critical assembly/disassembly sequences. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Searchability: Searchable text, allowing for quick keyword lookups of parts, systems, and procedures. Print Quality Resolution: High-resolution scans of original factory documentation, ensuring clarity of text and diagrams. Illustrations: Includes detailed line drawings, exploded views, and wiring diagrams crucial for repair and diagnosis. Binding Type Digital Binding: N/A (Digital format) Paper Type Digital Paper Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Code 1: 420A Engine Type 1: 2.0L (1996cc) SOHC Inline 4-cylinder (16-valve) Bore X Stroke 1: 87.5 mm x 83.0 mm Compression Ratio 1: 9.3:1 Horsepower 1: 132 hp @ 6000 rpm Torque 1: 124 lb-ft @ 4500 rpm Optional Engine Engine Code 2: DOHC 420B (16V) Engine Type 2: 2.0L (1996cc) DOHC Inline 4-cylinder (16-valve) with dual overhead camshafts (Exclusive to ACR, R/T models) Horsepower 2: 145 hp @ 6000 rpm Torque 2: 137 lb-ft @ 5000 rpm Performance Engine Management: Electronic Fuel Injection (EFI), Multi-Point Injection (MPI). Emission Controls: Catalytic converter, EGR system, PCV system. Fuel System Fuel Type: Unleaded gasoline (87 octane recommended, higher for performance models) Fuel Delivery: Electric fuel pump, fuel filter, fuel pressure regulator. 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Manual Transmission Source: Getrag Optional Transmission Type: 3-speed Automatic Transmission Automatic Transmission Model: A500 / 42LE family Features Clutch Type: Hydraulically actuated dry single-plate clutch (Manual). Transmission Fluid Manual: API GL-3 or GL-4, SAE 75W-90 synthetic gear oil. Transmission Fluid Automatic: Chrysler ATF+4 (or equivalent specification) - Refer to manual for precise fluid type and change intervals. 📐 Dimensions Exterior Length Sedan: Approx. 174.0 inches (4420 mm) Length Coupe: Approx. 170.5 inches...

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Description

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Year:

Codes

Platform Code:

👋 Introduction

Market Position

Segment:

Compact car

Target Audience:

Budget-conscious buyers, first-time car owners, DIY enthusiasts, automotive repair shops.

Competitive Analysis

Key Competitors:

Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier, Mitsubishi Eclipse.

Distinguishing Features:

Aggressive styling (for its era), surprisingly spacious interior for its size, availability of spirited performance variants (ACR/R/T).

Key Features

Design Philosophy:

Compact, aerodynamic, driver-focused interior, emphasis on value and performance.

Body Styles:

2-door coupe, 4-door sedan.

📋 Manual Details

Coverage Areas

Primary Coverage:

1999 Chrysler Neon (all trims and engines)

Secondary Coverage:

Related models using shared components or platforms

Page Count

Estimated Pages:

Approximately 1500-2000

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF, e-book)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

2.0L SOHC (16-valve), 2.0L DOHC (16-valve - ACR/R/T models), disassembly, inspection, reassembly, timing, seals, gaskets, pistons, rings, bearings, cylinder head, valve train, crankshaft, camshafts.

Engine Performance:

Fuel injection (MPI), ignition system, emissions control, cooling system, lubrication system, engine mounts.

Transmission Manual:

5-speed manual transmission (Getrag-sourced), clutch system, gear shifting mechanisms, internal components, fluid specifications.

Transmission Automatic:

3-speed automatic transmission (Chrysler A500/42LE family), torque converter, valve body, planetary gears, hydraulic system, fluid specifications, cooling.

Brakes:

Front disc brakes (Vented), rear drum brakes, ABS (Antilock Braking System) diagnosis and repair, brake fluid specifications, hydraulic lines, parking brake.

Suspension:

Front MacPherson struts, rear independent multi-link suspension, shock absorbers, springs, bushings, alignment specifications, wheel bearing replacement.

Steering:

Power steering system (rack and pinion), hydraulic pump, steering gear, tie rod ends, steering column, universal joints.

Electrical System:

12V battery system, charging system (alternator), starting system (starter motor), fuses, relays, wiring diagrams, lighting system, instrumentation, power windows, power locks, horn.

Body And Interior:

Body panel repair, door mechanisms, glass replacement, interior trim removal, seat removal, dashboard components, HVAC system (heater, A/C), body sealing.

Diagnostics And Troubleshooting:

OBD-II diagnostic trouble codes (DTCs), diagnostic procedures for all major systems, component testing, symptom-based troubleshooting guides.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, belt inspection/replacement, air filter replacement.

Engine Repair:

Head gasket replacement, timing belt/chain service, piston and ring replacement, bearing replacement, oil seal replacement, complete engine overhaul.

Transmission Service:

Clutch replacement, transmission fluid and filter changes, internal transmission repairs (manual and automatic), torque converter replacement.

Brake Service:

Brake pad/shoe replacement, rotor/drum replacement, caliper rebuild, ABS sensor replacement, brake line repair/replacement.

Suspension And Steering Repair:

Strut replacement, ball joint replacement, tie rod end replacement, power steering pump replacement, wheel alignment adjustment.

Electrical Diagnosis And Repair:

Starter/alternator testing, wiring harness repair, component testing (sensors, actuators), diagnostic tool usage, ECU troubleshooting.

Bodywork And Trim:

Door panel removal, interior trim replacement, glass installation, bumper repair, panel alignment.

HVAC Service:

Evaporator/condenser replacement, blower motor replacement, refrigerant handling (with proper certifications), cabin air filter replacement.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to full engine/transmission rebuilds and complex electrical diagnostics.

Diagnostic Focus:

Detailed diagnostic flowcharts, symptom analysis, and specific troubleshooting procedures for common and uncommon faults.

Repair Instructions:

Step-by-step repair instructions with torque specifications, special tool requirements, and critical assembly/disassembly sequences.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Searchability:

Searchable text, allowing for quick keyword lookups of parts, systems, and procedures.

Print Quality

Resolution:

High-resolution scans of original factory documentation, ensuring clarity of text and diagrams.

Illustrations:

Includes detailed line drawings, exploded views, and wiring diagrams crucial for repair and diagnosis.

Binding Type

Digital Binding:

N/A (Digital format)

Paper Type

Digital Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

Engine Type 1:

2.0L (1996cc) SOHC Inline 4-cylinder (16-valve)

Bore X Stroke 1:

87.5 mm x 83.0 mm

Compression Ratio 1:

9.3:1

Horsepower 1:

132 hp @ 6000 rpm

Torque 1:

124 lb-ft @ 4500 rpm

Optional Engine

Engine Code 2:

DOHC 420B (16V)

Engine Type 2:

2.0L (1996cc) DOHC Inline 4-cylinder (16-valve) with dual overhead camshafts (Exclusive to ACR, R/T models)

Horsepower 2:

145 hp @ 6000 rpm

Torque 2:

137 lb-ft @ 5000 rpm

Performance

Engine Management:

Electronic Fuel Injection (EFI), Multi-Point Injection (MPI).

Emission Controls:

Catalytic converter, EGR system, PCV system.

Fuel System

Fuel Type:

Unleaded gasoline (87 octane recommended, higher for performance models)

Fuel Delivery:

Electric fuel pump, fuel filter, fuel pressure regulator.

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transmission

Manual Transmission Source:

Getrag

Optional

Transmission Type:

3-speed Automatic Transmission

Automatic Transmission Model:

A500 / 42LE family

Features

Clutch Type:

Hydraulically actuated dry single-plate clutch (Manual).

Transmission Fluid Manual:

API GL-3 or GL-4, SAE 75W-90 synthetic gear oil.

Transmission Fluid Automatic:

Chrysler ATF+4 (or equivalent specification) - Refer to manual for precise fluid type and change intervals.

📐 Dimensions

Exterior

Length Sedan:

Approx. 174.0 inches (4420 mm)

Length Coupe:

Approx. 170.5 inches (4331 mm)

Width:

Approx. 67.4 inches (1712 mm)

Height Sedan:

Approx. 54.2 inches (1377 mm)

Height Coupe:

Approx. 53.3 inches (1354 mm)

Wheelbase:

Approx. 104.4 inches (2652 mm)

Track Width Front:

Approx. 57.5 inches (1460 mm)

Track Width Rear:

Approx. 57.6 inches (1463 mm)

Interior

Passenger Volume:

Approx. 95-100 cu ft (depending on body style)

Cargo

Trunk Volume Sedan:

Approx. 13.2 cu ft

Trunk Volume Coupe:

Approx. 11.3 cu ft

Weights

Curb Weight Manual:

Approx. 2700-2850 lbs (1225-1293 kg)

Curb Weight Automatic:

Approx. 2800-2950 lbs (1270-1338 kg)

Gross Vehicle Weight Rating:

Approx. 3700-3850 lbs (1678-1746 kg)

🛡️ Safety Features

Ratings

NHTSA Driver Front Impact:

4-star (for 1999 model)

NHTSA Passenger Front Impact:

4-star (for 1999 model)

Active Features

Available (standard on some higher trims like R/T, optional on others)

Traction Control:

Rarely available, typically not a standard feature for this generation.

Passive Features

Airbags:

Driver and passenger front airbags standard.

Seat Belts:

Front 3-point height-adjustable, rear 3-point belts. Pre-tensioners may be present on front belts.

Child Seat Anchors:

LATCH system not standard; ISOFIX equivalent may not be present or common.

💡 Technology Features

Infotainment

Radio Options:

AM/FM stereo with cassette tape player, optional CD player. Speaker configurations varied by trim.

Display:

Basic analog gauges for speedometer, tachometer (optional), fuel, and temperature. No central digital display or infotainment screen.

Driver Assistance

Cruise Control:

Optional on many trims, standard on higher performance models.

Anti Lock Brakes:

Available option, not standard on all models. Manual provides detailed ABS diagnosis.

Connectivity

Auxiliary Input:

Not available. Cassette adapter for MP3 players was a common aftermarket solution.

Bluetooth:

Not available from the factory.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles (5,000-12,000 km) or 6-12 months, depending on oil type and driving conditions (refer to manual for specific recommendations).

Engine Coolant Change:

Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years, using Mopar OAT coolant or equivalent.

Transmission Fluid Change Automatic:

Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years. Filter change recommended with fluid service.

Transmission Fluid Change Manual:

Every 60,000-100,000 miles (96,000-160,000 km) or 4-6 years.

Spark Plug Replacement:

Every 30,000-100,000 miles (48,000-160,000 km) depending on plug type (standard copper vs. platinum/iridium).

Timing Belt Replacement:

The 420A engine uses a timing belt. Replacement interval is critical, typically around 90,000-100,000 miles (145,000-160,000 km) or 7 years. Failure can cause catastrophic engine damage. The DOHC engine typically uses a timing chain which has a longer service life.

Fluid Specifications

Engine Oil Specification:

SAE 5W-30 or 5W-40 (API certified, ILSAC certified)

Engine Oil Capacity:

Approx. 4.5 US quarts (4.3 L) with filter for 2.0L engines.

Coolant Specification:

Mopar OAT (Organic Acid Technology) 5-year/100,000 mile coolant or equivalent HOAT/OAT compatible coolant.

Brake Fluid Specification:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

ATF +3 or ATF +4, or specific Mopar power steering fluid.

Known Issues

Engine Oil Leaks:

Common for valve cover gaskets and crankshaft seals to leak over time.

Timing Belt Failure:

Critical to adhere to replacement intervals on the 420A SOHC engine. Broken belts cause valve-to-piston contact.

Automatic Transmission Harsh Shifting:

Can occur due to solenoid issues, low fluid pressure, or aging valve body components.

Suspension Wear:

Worn ball joints, tie rod ends, and strut mounts are common due to age and mileage.

Cooling System Leaks:

Plastic end tanks on radiators and heater cores can crack, leading to coolant leaks.

Electrical Connector Corrosion:

Corrosion in engine bay and under-dash connectors can cause intermittent electrical faults.

📚 Vehicle History

Brand Heritage

Chrysler History:

Chrysler Corporation, a major American automotive manufacturer, known for its diverse range of vehicles from luxury sedans to compact cars. The Neon represented Chrysler's foray into the highly competitive compact car segment.

Model Evolution

First Generation Launch:

First generation (PG) launched for the 1995 model year. The 1999 model year represents the latter part of this first generation, receiving minor updates.

Platform Development:

The PL platform was designed with global appeal in mind and was known for its rigid unibody construction.

Performance Variants:

The 'ACR' (American Club Racer) and 'R/T' trims offered enhanced suspension, brakes, and the more powerful DOHC engine, appealing to a more enthusiast-driven market.

Production

Manufacturing Locations:

Belvidere, Illinois, USA.

Production Years:

1995-2005 (First generation: 1995-2000, Second generation: 2000-2005).

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The first generation Neon was named to Car and Driver's 10Best list for 1996 and 1997, recognizing its value, handling, and sporty nature.

Motor Trend Car Of The Year Nominee:

Competed for Motor Trend Car of the Year in its debut year.