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Chrysler Neon Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Neon Codes Platform Code: PL platform 👋 Introduction Market Position Segment: Compact Car Target Audience: Value-conscious buyers, DIY enthusiasts, professional mechanics Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Ford Escort, Chevrolet Cavalier, Mitsubishi Eclipse, Hyundai Elantra Key Features Unique Selling Points: Affordability, sporty handling (especially SXT/ACR/SRT-4 trims), spacious interior for its class, distinctive styling 📋 Manual Details Coverage Areas Primary Coverage Years: 1995-2005 Engine Variants Covered: 2.0L SOHC I4, 2.0L DOHC I4 (including ACR/SRT-4 variants) Transmission Types Covered: 3-speed automatic, 4-speed automatic, 5-speed manual Page Count Estimated Pages: 2000-3000 (comprehensive workshop manual) Manual Type Manual Classification: Factory Service Manual / Workshop Manual Language Language: English Format Format Type: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain Systems: Engine mechanical, fuel system, ignition system, exhaust system, engine management, cooling system, lubrication system, clutch, manual transmission, automatic transmission, driveline, axle components Chassis Systems: Suspension (front and rear), steering system, brake system (front and rear disc, ABS components), wheels and tires Electrical Systems: Battery, charging system, starting system, lighting, instrument cluster, wiring diagrams, body control modules, engine control modules (ECM), transmission control modules (TCM), power windows, power locks, HVAC controls, audio system Body And Interior: Body panels, doors, glass, seats, interior trim, HVAC system operation, body sealing Procedures Included Maintenance Procedures: Scheduled maintenance intervals, fluid changes (oil, coolant, transmission fluid, brake fluid), filter replacements, belt inspection/replacement, spark plug replacement, diagnostic checks Repair Procedures: Engine overhaul, transmission repair/rebuild, brake component replacement, suspension component replacement, steering system repair, electrical component diagnosis and replacement, body panel repair Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting guides, common problem diagnosis (e.g., misfires, starting issues, transmission slipping), fault code interpretation (OBD-II) Technical Depth Diagnostic Capabilities: Advanced diagnostics, including wiring diagrams, component testing procedures, sensor data interpretation, and ECM/TCM calibration Rebuild Instructions: Detailed step-by-step instructions for engine and transmission rebuilds, including torque specifications, clearances, and assembly sequences 📊 Manual Specifications File Format Digital Format: PDF Searchability: Full text searchability Print Quality Digital Resolution: High resolution for clear diagrams and text Binding Type Binding: N/A (Digital) Paper Type Paper Quality: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Code Base: 420A (2.0L SOHC) Engine Code Performance: ECC/ESK (2.0L DOHC) Performance Base Engine Horsepower: 118 hp @ 5500 rpm Base Engine Torque: 123 lb-ft @ 3000 rpm DOHc Engine Horsepower: 132 hp @ 6000 rpm (standard DOHC) DOHc Engine Torque: 130 lb-ft @ 4500 rpm (standard DOHC) Srt-4 Engine Horsepower: 200-215 hp @ 5200-5800 rpm (turbocharged) Srt-4 Engine Torque: 220-245 lb-ft @ 2200-3000 rpm (turbocharged) Fuel System Fuel Delivery: Multi-port Fuel Injection (MPFI) Recommended Fuel: 87 Octane (for SOHC/DOHC), 91 Octane Premium (for SRT-4) Emissions System: OBD-II compliant, catalytic converter 🔧 Transmission Standard Standard Transmission: 5-speed Manual Optional Optional Transmission 1: 3-speed Automatic (early models) Optional Transmission 2: 4-speed Automatic (later models) Features Manual Transmission Clutch Type: Hydraulically Actuated Dry Clutch Automatic Transmission Control: Electronic Control Unit (ECU) managed Manual Transmission Fluid Type: MS-9070 (API GL-4, SAE 75W-90) Automatic Transmission Fluid Type: ATF+4 (Chrysler spec) 📐 Dimensions Exterior Length: 163.8 - 174.9 inches (depending on generation/body style) Width: 66.9 - 67.7 inches Height: 53.9 - 55.7 inches Wheelbase: 104.4 inches Cargo Trunk Volume: 13.0 - 15.3 cu ft (sedan), 20.0 cu ft (hatchback, expandable) Weights Curb Weight: 2600 - 3100 lbs (depending on configuration) 🛡️ Safety Features Ratings NHTSA Front Impact Rating: Good (driver), Acceptable (passenger) - early models IIHS Side Impact Rating: Acceptable (early models) Active Features ABS: Available (standard on higher trims and later years) Traction Control: Available on some models (especially SRT-4) Passive Features Airbags: Driver and front passenger airbags standard, optional side airbags on some models Seatbelts: 3-point front and rear seat belts 💡 Technology Features Infotainment Audio System: AM/FM stereo with cassette and/or CD player, optional premium sound system Display Type: Basic LCD or digital display for radio/clock Driver Assistance Cruise Control: Available Remote Keyless Entry: Available on higher trims Connectivity OBD Ii Port: Standard for diagnostics 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles or 6 months (synthetic oil recommended) Air Filter Replacement: Every 30,000 miles or 2 years Spark Plug Replacement: Every 100,000 miles (Long-life Platinum/Iridium recommended) Coolant Flush: Every 60,000 miles or 5 years (OAT coolant) Fluid Specifications Engine Oil Type: SAE 5W-30 (API SN or higher) Engine Oil Capacity: 4.0 quarts (420A), 4.5 quarts (ECC/ESK) Coolant Type: Chrysler OAT (Organic Additive Technology) - Mopar OAT Antifreeze/Coolant Brake Fluid Type: DOT 3 Known Issues Common Engine Issues: Oil leaks (valve cover gasket, oil pan gasket), cooling system leaks (radiator, hoses), exhaust manifold cracks (older 420A engines), intake manifold gasket leaks, timing belt failure (if not replaced on schedule) Common Transmission Issues: Automatic transmission slipping or hard shifting, manual transmission clutch wear, synchronizer issues Common Suspension Issues: Worn ball joints, tie rod ends, wheel bearings, strut mounts...
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Sku: 584050
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Chrysler Neon Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Neon
Codes
Platform Code:
PL platform
👋 Introduction
Market Position
Segment:
Compact Car
Target Audience:
Value-conscious buyers, DIY enthusiasts, professional mechanics
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Ford Escort, Chevrolet Cavalier, Mitsubishi Eclipse, Hyundai Elantra
Key Features
Unique Selling Points:
Affordability, sporty handling (especially SXT/ACR/SRT-4 trims), spacious interior for its class, distinctive styling
📋 Manual Details
Coverage Areas
Primary Coverage Years:
1995-2005
Engine Variants Covered:
2.0L SOHC I4, 2.0L DOHC I4 (including ACR/SRT-4 variants)
Transmission Types Covered:
3-speed automatic, 4-speed automatic, 5-speed manual
Page Count
Estimated Pages:
2000-3000 (comprehensive workshop manual)
Manual Type
Manual Classification:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format Type:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain Systems:
Engine mechanical, fuel system, ignition system, exhaust system, engine management, cooling system, lubrication system, clutch, manual transmission, automatic transmission, driveline, axle components
Chassis Systems:
Suspension (front and rear), steering system, brake system (front and rear disc, ABS components), wheels and tires
Electrical Systems:
Battery, charging system, starting system, lighting, instrument cluster, wiring diagrams, body control modules, engine control modules (ECM), transmission control modules (TCM), power windows, power locks, HVAC controls, audio system
Body And Interior:
Body panels, doors, glass, seats, interior trim, HVAC system operation, body sealing
Procedures Included
Maintenance Procedures:
Scheduled maintenance intervals, fluid changes (oil, coolant, transmission fluid, brake fluid), filter replacements, belt inspection/replacement, spark plug replacement, diagnostic checks
Repair Procedures:
Engine overhaul, transmission repair/rebuild, brake component replacement, suspension component replacement, steering system repair, electrical component diagnosis and replacement, body panel repair
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting guides, common problem diagnosis (e.g., misfires, starting issues, transmission slipping), fault code interpretation (OBD-II)
Technical Depth
Diagnostic Capabilities:
Advanced diagnostics, including wiring diagrams, component testing procedures, sensor data interpretation, and ECM/TCM calibration
Rebuild Instructions:
Detailed step-by-step instructions for engine and transmission rebuilds, including torque specifications, clearances, and assembly sequences
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Full text searchability
Print Quality
Digital Resolution:
High resolution for clear diagrams and text
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Quality:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code Base:
420A (2.0L SOHC)
Engine Code Performance:
ECC/ESK (2.0L DOHC)
Performance
Base Engine Horsepower:
118 hp @ 5500 rpm
Base Engine Torque:
123 lb-ft @ 3000 rpm
DOHc Engine Horsepower:
132 hp @ 6000 rpm (standard DOHC)
DOHc Engine Torque:
130 lb-ft @ 4500 rpm (standard DOHC)
Srt-4 Engine Horsepower:
200-215 hp @ 5200-5800 rpm (turbocharged)
Srt-4 Engine Torque:
220-245 lb-ft @ 2200-3000 rpm (turbocharged)
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPFI)
Recommended Fuel:
87 Octane (for SOHC/DOHC), 91 Octane Premium (for SRT-4)
Emissions System:
OBD-II compliant, catalytic converter
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual
Optional
Optional Transmission 1:
3-speed Automatic (early models)
Optional Transmission 2:
4-speed Automatic (later models)
Features
Manual Transmission Clutch Type:
Hydraulically Actuated Dry Clutch
Automatic Transmission Control:
Electronic Control Unit (ECU) managed
Manual Transmission Fluid Type:
MS-9070 (API GL-4, SAE 75W-90)
Automatic Transmission Fluid Type:
ATF+4 (Chrysler spec)
📐 Dimensions
Exterior
Length:
163.8 - 174.9 inches (depending on generation/body style)
Width:
66.9 - 67.7 inches
Height:
53.9 - 55.7 inches
Wheelbase:
104.4 inches
Cargo
Trunk Volume:
13.0 - 15.3 cu ft (sedan), 20.0 cu ft (hatchback, expandable)
Weights
Curb Weight:
2600 - 3100 lbs (depending on configuration)
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
Good (driver), Acceptable (passenger) - early models
IIHS Side Impact Rating:
Acceptable (early models)
Active Features
ABS:
Available (standard on higher trims and later years)
Traction Control:
Available on some models (especially SRT-4)
Passive Features
Airbags:
Driver and front passenger airbags standard, optional side airbags on some models
Seatbelts:
3-point front and rear seat belts
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with cassette and/or CD player, optional premium sound system
Display Type:
Basic LCD or digital display for radio/clock
Driver Assistance
Cruise Control:
Available
Remote Keyless Entry:
Available on higher trims
Connectivity
OBD Ii Port:
Standard for diagnostics
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 6 months (synthetic oil recommended)
Air Filter Replacement:
Every 30,000 miles or 2 years
Spark Plug Replacement:
Every 100,000 miles (Long-life Platinum/Iridium recommended)
Coolant Flush:
Every 60,000 miles or 5 years (OAT coolant)
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (API SN or higher)
Engine Oil Capacity:
4.0 quarts (420A), 4.5 quarts (ECC/ESK)
Coolant Type:
Chrysler OAT (Organic Additive Technology) - Mopar OAT Antifreeze/Coolant
Brake Fluid Type:
DOT 3
Known Issues
Common Engine Issues:
Oil leaks (valve cover gasket, oil pan gasket), cooling system leaks (radiator, hoses), exhaust manifold cracks (older 420A engines), intake manifold gasket leaks, timing belt failure (if not replaced on schedule)
Common Transmission Issues:
Automatic transmission slipping or hard shifting, manual transmission clutch wear, synchronizer issues
Common Suspension Issues:
Worn ball joints, tie rod ends, wheel bearings, strut mounts
Common Electrical Issues:
Window motor failures, power lock actuator issues, instrument cluster problems (dimming gauges), intermittent electrical gremlins due to poor grounds
Common Body Issues:
Rust (especially on rocker panels, wheel wells, and rear quarters), door seal degradation
📚 Vehicle History
Brand Heritage
Brand Origin:
American automotive manufacturer, founded by Walter Chrysler
Model Evolution
First Generation:
1995-2000 (PS platform), known for its distinctive "cab-forward" design and sporty variants
Second Generation:
2000-2005 (BC platform), redesigned with a more conventional look, improved interior, and introduction of the SRT-4 model
Production
Manufacturing Location:
Belvidere Assembly Plant, Illinois, USA
Production Years:
1994-2005
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
Car and Driver 10 Best list (1996)
Ratings
Jd Power Dependability:
Varied depending on year and specific model, generally average to below average for its segment historically
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