Dodge Neon 1999 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Neon Year: 1999 Codes Platform: PL (first generation) 👋 Introduction Market Position Vehicle Segment: Compact car, known for its affordability and sporty driving...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Year:

Codes

Platform:

PL (first generation)

👋 Introduction

Market Position

Vehicle Segment:

Compact car, known for its affordability and sporty driving dynamics.

Competitive Analysis

Key Competitors:

Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier, Nissan Sentra.

Key Features

Design Philosophy:

Designed as a successor to the Dodge Colt, emphasizing European styling cues and a focus on handling.

Performance Orientated:

Many models offered with optional performance engines and suspension tuning, appealing to enthusiasts.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive repair and overhaul procedures for the 1999 Dodge Neon.

Specific Systems:

Engine, transmission, drivetrain, suspension, steering, brakes, HVAC, electrical, fuel system, emissions, body, interior, diagnostics.

Page Count

Estimated Pages:

Over 2000 (typical for a full workshop manual)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed breakdown of engine assembly, disassembly, inspection, and repair for all engine variants. Includes cylinder head, block, crankshaft, pistons, connecting rods, valvetrain.

Engine Performance:

Engine tuning, performance adjustments, diagnosis of performance-related issues, and specifications for optimal engine operation.

Fuel System:

Fuel injection system operation, fuel pump testing, injector servicing, fuel filter replacement, fuel pressure diagnosis, and evaporative emission control (EVAP) system.

Ignition System:

Spark plug specifications, ignition coil testing, distributor diagnosis (if applicable), ignition timing procedures, and crankshaft/camshaft position sensor diagnosis.

Cooling System:

Radiator, water pump, thermostat, cooling fan operation, coolant specifications, pressure testing, and diagnosis of overheating issues.

Exhaust System:

Catalytic converter inspection and replacement, muffler and pipe diagnosis, oxygen sensor testing, and exhaust leak troubleshooting.

Transmission Manual:

Complete overhaul procedures for manual transmissions, including clutch inspection and replacement, gear synchronization, bearing service, and fluid specifications.

Transmission Automatic:

Diagnosis, repair, and overhaul of automatic transmissions, including torque converter service, valve body operation, planetary gear sets, and transmission fluid specifications.

Drivetrain:

Front-wheel drive axle shaft inspection and replacement, CV joint servicing, differential operation, and driveshaft (if applicable) maintenance.

Suspension Front:

Strut and shock absorber replacement, control arm servicing, ball joint inspection, stabilizer bar linkage, and wheel bearing replacement.

Suspension Rear:

Rear shock absorber replacement, trailing arm bushings, suspension geometry adjustments, and rear axle servicing.

Steering System:

Power steering pump diagnosis and replacement, steering rack servicing, tie rod end inspection, and alignment procedures.

Brake System Front:

Front disc brake pad replacement, rotor resurfacing/replacement, caliper servicing, and brake line routing.

Brake System Rear:

Rear drum brake adjustment and relining (if applicable), disc brake service (if applicable), parking brake adjustment, and brake fluid specifications.

Anti Lock Brakes:

ABS sensor diagnosis, hydraulic modulator operation, ABS warning light troubleshooting, and system bleeding procedures.

Body Exterior:

Door panel removal, hood and trunk latch servicing, mirror replacement, bumper removal and installation, and paint repair guidelines.

Body Interior:

Seat removal and installation, dashboard disassembly, headliner servicing, carpet replacement, and trim piece removal.

Climate Control HVAC:

A/C system refrigerant handling and charging, blower motor diagnosis, heater core replacement, cabin air filter replacement, and temperature control system troubleshooting.

Electrical System Lighting:

Headlight, taillight, and interior lighting bulb replacement, wiring harness diagrams for lighting circuits, and fuse/relay identification.

Electrical System Instruments:

Instrument cluster diagnosis and repair, speedometer, tachometer, fuel gauge, and warning lamp troubleshooting.

Electrical System Power:

Battery testing and replacement, alternator diagnosis and replacement, starter motor operation, and power distribution systems.

Electrical System Accessories:

Power window motor replacement, central locking system diagnosis, sunroof operation, and wiper motor servicing.

Body Control Module:

Diagnosis and potential reprogramming of body control modules, keyless entry system troubleshooting.

Airbags:

Airbag system components, diagnostic procedures for airbag faults, and safety precautions for handling airbag systems.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, fuel filter replacement, coolant flush and fill, brake fluid flush.

Troubleshooting:

Systematic diagnostic charts for common symptoms, fault codes and their meanings, and step-by-step troubleshooting guides.

Repair Overhaul:

Detailed instructions for component removal, repair, reassembly, and installation for nearly all vehicle systems.

Alignment And Balancing:

Wheel alignment specifications and procedures, tire balancing, and wheel mounting.

Wiring Diagrams:

Comprehensive electrical wiring schematics for all major systems, including engine, transmission, chassis, and body.

Diagnostic Procedures:

Specific diagnostic steps for various fault conditions, including use of diagnostic tools and interpretation of live data.

Specifications And Tolerances:

All essential torque specifications, clearances, and critical measurements for component assembly and adjustment.

Technical Depth

Depth Level:

Professional Workshop Level. Covers everything from basic fluid changes to complete engine and transmission rebuilds.

Diagnostic Focus:

In-depth diagnostic strategies for complex electrical and mechanical faults, including interpretation of OBD-II codes.

Component Rebuilds:

Detailed instructions for the complete disassembly, inspection, repair, and reassembly of major components like engines and transmissions.

📊 Manual Specifications

File Format

File Type:

Portable Document Format (PDF)

Searchability:

Likely text-searchable, allowing for quick access to specific information.

Print Quality

Image Resolution:

Variable, but typically high enough for clear diagrams and illustrations.

Illustration Clarity:

Expected to include clear, detailed diagrams, schematics, and photographs.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

2.0L SOHC (3000 SOHC) and 2.0L DOHC (3000 DOHC)

Engine Type:

Inline 4-cylinder, naturally aspirated

Displacement:

1996 cc (2.0 Liters)

Performance

Horsepower Sohc:

132 hp @ 6000 rpm

Torque Sohc:

130 lb-ft @ 4800 rpm

Horsepower DOHc:

150 hp @ 6000 rpm (ES, SE models)

Torque DOHc:

135 lb-ft @ 4800 rpm (ES, SE models)

Horsepower Srt 4 Variant:

Not applicable to 1999 model (introduced later)

Fuel System

Fuel Delivery:

Electronic Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline (87 octane recommended)

Engine Features

Block Material:

Aluminum Alloy

Cylinder Head Material:

Aluminum Alloy

Valve Train:

SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) with 16 valves total

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transmission

Optional

Transmission Type:

4-speed Automatic Transmission

Features

Clutch Type:

Hydraulically actuated, single dry plate

Automatic Transmission Control:

Electronic control unit (ECU) for shift logic

📐 Dimensions

Exterior

Length:

Approx. 161.9 inches (4112 mm)

Width:

Approx. 67.4 inches (1712 mm)

Height:

Approx. 53.9 inches (1369 mm)

Wheelbase:

Approx. 104.0 inches (2641 mm)

Track Width Front:

Approx. 58.0 inches (1473 mm)

Track Width Rear:

Approx. 57.8 inches (1468 mm)

Ground Clearance:

Approx. 5.0 inches (127 mm)

Weights

Curb Weight Manual:

Approx. 2600 lbs (1179 kg)

Curb Weight Automatic:

Approx. 2650 lbs (1202 kg)

Gross Vehicle Weight Rating:

Approx. 3500 lbs (1588 kg)

Cargo

Trunk Capacity:

Approx. 13.0 cubic feet (368 liters)

🛡️ Safety Features

Ratings

NHTSA Frontal Driver:

4-star (1999 model year tested)

NHTSA Frontal Passenger:

4-star (1999 model year tested)

IIHS Side Impact:

Acceptable (for vehicles equipped with side airbags, if available)

Active Features

Optional Anti-lock Braking System (ABS) on all four wheels.

Traction Control:

Not typically available on this model year.

Passive Features

Airbags Front:

Driver and front passenger airbags standard.

Airbags Side:

Optional front-seat side airbags available on some trims.

Seatbelts:

Three-point seatbelts for all occupants, pretensioners for front seats.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system not standard on this model year.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with cassette player standard, optional CD player. Aftermarket head units are common upgrades.

Driver Assistance

Cruise Control:

Optional cruise control system available on most trims.

Connectivity

Keyless Entry:

Optional keyless entry system.

Power Accessories

Power Windows Locks:

Optional power windows, power door locks, and power mirrors.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 to 5,000 miles (5,000 to 8,000 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 30,000 miles (48,000 km) for standard spark plugs, 60,000 miles (96,000 km) for platinum plugs.

Coolant Flush:

Every 30,000 miles (48,000 km) or 2 years.

Transmission Fluid Change Auto:

Every 30,000 miles (48,000 km) or 2 years. Filter replacement recommended during fluid change.

Transmission Fluid Change Manual:

Every 60,000 miles (96,000 km) or 4 years.

Brake Fluid Flush:

Every 2 years or 30,000 miles (48,000 km).

Fluid Specifications

Engine Oil Type:

SAE 5W-30 API Service SG or SH, SF

Engine Oil Capacity:

4.5 US quarts (4.2 liters) with filter

Coolant Type:

Ethylene Glycol based, Mopar Antifreeze/Coolant (50/50 mix with distilled water)

Transmission Fluid Type Auto:

Chrysler ATF+3 (MS-9224) or equivalent

Transmission Fluid Type Manual:

SAE 75W-90 API GL-4 gear oil (specific Mopar part numbers may apply)

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

ATF+3 or Mopar Power Steering Fluid

Known Issues

Engine Mounts:

Premature wear and failure of engine and transmission mounts, leading to vibration and noise.

Suspension Components:

Wear in front control arm bushings, ball joints, and tie rod ends; rear trailing arm bushings also prone to wear.

Oil Leaks:

Valve cover gasket and oil pan gasket leaks are common.

Cooling System:

Leaking radiator, water pump seal failures, and heater core leaks.

Ignition System:

Coil pack failures leading to misfires, faulty crankshaft position sensors.

Interior Components:

Window regulators failing, door panel clips breaking, instrument cluster gauge failure.

Exhaust System:

Corrosion and failure of mufflers and exhaust pipes.

📚 Vehicle History

Brand Heritage

Parent Company:

Chrysler Corporation (later DaimlerChrysler)

Model Evolution

Generation:

First Generation (1995-2000)

Redesign Year:

The 1999 model year represents a late iteration of the first generation, with minor updates from previous years.

Production

Manufacturing Plant:

Sterling Heights, Michigan, USA; Toluca, Mexico

Production Years:

1995-2000 (First Generation)

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The Dodge Neon was named to Car and Driver's 10Best list in 1996, highlighting its chassis dynamics and value.

Ratings

Consumer Reports:

Consumer Reports ratings for the 1999 model year generally indicated average to below-average reliability across various systems.

Certifications

Emissions Compliance:

Meets EPA emissions standards for the 1999 model year.