2000 DODGE NEON Service Repair Manual

GROUP TAB LOCATORINIntroductionINaIntroduction0Lubrication and Maintenance2Suspension3Differential and Driveline5Brakes6Clutch7Cooling8ABattery8BStarting8CCharging System8DIgnition System8EInstrument Panel and Systems8EaInstrument Panel and Systems8FAudio System8GHorns8HVehicle Speed Control System8JTurn Signal and Flashers8KWindshield Wipers and Washers8LLamps8LaLamps8MRestraint System8NElectrically Heated Systems8OPower Distribution Systems8PPower Door Locks8QImmobilizer System8SPower Windows8TPower Mirrors8TaPower Mirrors8UChime Warning/Reminder System8WWiring Diagrams - LHD and RHD9Engine11Exhaust System13Frame and Bumpers14Fuel System19Steering21Transaxle22Tires and Wheels23Body24Heating and Air Conditioning24aHeating and Air Conditioning25Emission Control Systems

LUBRICATION AND MAINTENANCE
TABLE OF CONTENTS
page page
LUBRICANTS............................. 1
MAINTENANCE SCHEDULES................. 3JUMP STARTING, TOWING, AND HOISTING..... 7
LUBRICANTS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
PARTS AND LUBRICANT
RECOMMENDATIONS....................1
CLASSIFICATION OF LUBRICANTS............1
INTERNATIONAL SYMBOLS.................2FLUID CHECK/FILL POINTS AND
LUBRICATION LOCATIONS.................2
LUBRICATION POINT LOCATIONS............2
SPECIFICATIONS
FLUID CAPACITIES........................2
DESCRIPTION AND OPERATION
PARTS AND LUBRICANT RECOMMENDATIONS
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopartbrand parts,
lubricants and chemicals be used. Mopar provides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
CLASSIFICATION OF LUBRICANTS
DESCRIPTION
Only lubricants bearing designations defined by
the following organization should be used to service a
DaimlerChrysler Corporation vehicle.
²Society of Automotive Engineers (SAE)
²American Petroleum Institute (API) (Fig. 1)
²National Lubricating Grease Institute (NLGI)
(Fig. 2)
SAE VISCOSITY RATING
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. These are specified with a dual
SAE viscosity grade which indicates the cold-to-hot
temperature viscosity range. Example SAE 5W-30 =
multiple grade engine oil.DaimlerChrysler Corporation only recommends
multiple grade engine oils.
API QUALITY CLASSIFICATION
This symbol (Fig. 1) on the front of an oil container
means that the oil has been certified by the Ameri-
can Petroleum Institute (API) to meet all the lubri-
cation requirements specified by DaimlerChrysler
Corporation.
Refer to Group 9, Engine for gasoline engine oil
specification.
GEAR LUBRICANTS
SAE ratings also apply to multiple grade gear
lubricants. In addition, API classification defines the
lubricants usage. Such as API GL-5 and SAE 80W-90.
Fig. 1 API Symbol
PLLUBRICATION AND MAINTENANCE 0 - 1

LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 2) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
ªGº. Chassis lubricant is identified by the latter ªLº.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
INTERNATIONAL SYMBOLS
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid check and fill locations (Fig. 3).
FLUID CHECK/FILL POINTS AND LUBRICATION
LOCATIONS
The fluid check/fill points and lubrication locations
are located in each applicable Sections.
LUBRICATION POINT LOCATIONS
Lubrication point locations are located in each
applicable Sections.
SPECIFICATIONS
FLUID CAPACITIES
Fuel Tank (approximate)....47.5 Liter (12.5 gal.)
Engine Oil ± With Filter....... 4.3Liter (4.5 qts.)
Engine Oil ± Without Filter.... 3.8Liter (4.0 qts.)
Cooling System ± Includes Heater & Coolant
Recovery Bottle*........... 6.2Liter (6.5 qts.)
Automatic Transaxle ± Estimated Service
Fill........................ 3.8L(4.0 qts.)
Automatic Transaxle ± 31 TH ± Overhaul Fill
Capacity with Torque Converter Empty . . . 8.4 L
(8.9. qts.)
Manual Transaxle ± NV T350........ 1.9to2.2L
(4.0 to 4.6 pts.)
*Capacities include 1 qt. for coolant reserve tank.
Fig. 2 NLGI Symbol
1 ± WHEEL BEARINGS
2 ± CHASSIS LUBRICATION
3 ± CHASSIS AND WHEEL BEARINGS
Fig. 3 International Symbols
0 - 2 LUBRICATION AND MAINTENANCEPL
DESCRIPTION AND OPERATION (Continued)

MAINTENANCE SCHEDULES
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
MAINTENANCE SCHEDULES................3
SPECIFICATIONS
UNSCHEDULED INSPECTION................3SCHEDULE ± A...........................3
SCHEDULE ± B...........................4
DESCRIPTION AND OPERATION
MAINTENANCE SCHEDULES
There are two maintenance schedules that show
proper service for your vehicle.
First is Schedule ±A. It lists all the scheduled
maintenance to be performed under ªnormalº operat-
ing conditions.
Second is Schedule ±B. It is a schedule for vehi-
cles that are operated under the following conditions:
²Frequent short trip driving less than 5 miles (8
km)
²Frequent driving in dusty conditions
²Extensive idling
²More than 50% of the driving is at sustained
high speeds during hot weather, above 90É F (32É C)
SPECIFICATIONS
UNSCHEDULED INSPECTION
At Each Stop For Fuel
²Check engine oil level and add as required.
²Check windshield washer solvent and add as
required.
Once A Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect the battery and clean and tighten termi-
nals as required.
²Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission.
Add fluid as required.
²Check all lights and all other electrical items for
correct operation.
At Each Oil Change
²Inspect the exhaust system.
²Inspect brake hoses.
²Inspect the CV joints and front suspension com-
ponent boots and seals.²Rotate the tires at each oil change interval
shown on Schedule ± A (7,500 miles - 12 000 km) or
every other interval on Schedule ± B (6,000 miles -
10 000 km).
²Check the engine coolant level, hoses, and
clamps.
If mileage is less than 7,500 miles (12 000 km)
yearly, replace the engine oil filter at each oil change.
EMISSION CONTROL SYSTEM MAINTENANCE
The scheduled emission maintenance listed inbold
typeon the Maintenance Schedules, must be done at
the mileage specified to assure the continued proper
functioning of the emission control system. These,
and all other maintenance services included in this
manual, should be done to provide the best vehicle
performance and reliability. More frequent mainte-
nance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.
FLUID FILL POINTS AND LUBRICATION
LOCATIONS
The fluid fill/check locations and lubrication loca-
tions are located in each applicable group.
SCHEDULE ± A
7,500 Miles (12 000 km) or at 6 months
²Change the engine oil.
²Replace the engine oil filter.
15,000 Miles (24 000 km) or at 12 months
²Change the engine oil.
²Replace the engine oil filter.
²Adjust the drive belt tension.
22,500 Miles (36 000 km) or at 18 months
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the front brake pads and rear brake lin-
ings.
PLLUBRICATION AND MAINTENANCE 0 - 3

30,000 Miles (48 000 km) or at 24 months
²Change the engine oil.
²Replace the engine oil filter.
²Lubricate the front suspension lower ball joint.
²Inspect the tie rod ends and boot seals.
²Adjust the drive belt tension.
²Replace the engine air cleaner element (fil-
ter).
²Replace the engine spark plugs
²Change the automatic transaxle fluid.
37,500 Miles (60 000 km) or at 30 months
²Change the engine oil.
²Replace the engine oil filter.
45,000 Miles (72 000 km) or at 36 months
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the front brake pads and rear brake lin-
ings.
²Adjust the drive belt tension.
²Flush and replace the engine coolant at 36
months, regardless of mileage.
52,500 Miles (84 000 km) or at 42 months
²Change the engine oil.
²Replace the engine oil filter.
²Flush and replace the engine coolant if not done
at 36 months.
60,000 Miles (96 000 km) or at 48 months
²Change the engine oil.
²Replace the engine oil filter.
²Check the PCV valve and replace, if neces-
sary. Not required if previously changed.*
²Lubricate the front suspension lower ball joints.
²Replace the drive belts.
²Replace the engine air cleaner element (fil-
ter).
²Replace the ignition cables.
²Replace the spark plugs.
²Change the automatic transaxle fluid.
67,500 Miles (108 000 km) or at 54 months
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the front brake pads and rear brake lin-
ings.
75,000 Miles (120 000 km) or at 60 months
²Change the engine oil.
²Replace the engine oil filter.
²Adjust the drive belt tension.
²Flush and replace engine coolant if has been
30,000 miles (48 000 km) or 24 months since last
change.
82,500 Miles (132 000 km) or at 66 months
²Change the engine oil.
²Replace the engine oil filter.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
90,000 Miles (144 000 km) or at 72 months
²Change the engine oil.
²Replace the engine oil filter.
²Check the PCV valve and replace, if neces-
sary. Not required if previously changed.*
²Lubricate the front suspension lower ball joints.
²Inspect the front brake pads and rear brake lin-
ings.
²Adjust the drive belt tension.
²Replace the engine air cleaner element (fil-
ter).
²Replace the spark plugs.
²Inspect the serpentine drive belt, replace if nec-
essary. This maintenance is not required if the belt
was previously replaced.
²Change the automatic transaxle fluid.
97,500 Miles (156 000 km) or at 78 months
²Change the engine oil.
²Replace the engine oil filter.
105,000 Miles (168 000 km) or at 84 months
²Change the engine oil.
²Replace the engine oil filter.
²Replace the engine timing belt.
²Adjust the drive belt tension.
*This maintenance is recommended by Daimler-
Chrysler Corporation to the owner but is not
required to maintain the emissions warranty.
NOTE: Inspection and service should also be per-
formed anytime a malfunction is observed or sus-
pected. Retain all receipts.
SCHEDULE ± B
3,000 Miles (5 000 km)
²Change the engine oil.
6,000 Miles (10 000 km)
²Change the engine oil.
²Replace the engine oil filter.
9,000 Miles (14 000 km)
²Change the engine oil.
²Inspect the front brake pads and rear brake lin-
ings.
0 - 4 LUBRICATION AND MAINTENANCEPL
SPECIFICATIONS (Continued)

12,000 Miles (19 000 km)
²Change the engine oil.
²Replace the engine oil filter.
15,000 Miles (24 000 km)
²Change the engine oil.
²Adjust the drive belt tension.
²Inspect theengine air cleaner element (fil-
ter).Replace as necessary.*
²Change the automatic transaxle fluid/filter and
adjust the bands.
18,000 Miles (29 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the front brake pads and rear brake lin-
ings.
21,000 Miles (34 000 km)
²Change the engine oil.
24,000 Miles (38 000 km)
²Change the engine oil.
²Replace the engine oil filter.
27,000 Miles (43 000 km)
²Change the engine oil.
²Inspect the front brake pads and rear brake lin-
ings.
30,000 Miles (48 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect thePCV valveand replace as neces-
sary.*
²Lubricate the front suspension lower ball joints.
²Adjust the drive belt tension.
²Replace theengine air cleaner element (fil-
ter).
²Replace thespark plugs
²Change the automatic transaxle fluid/filter and
adjust bands.
33,000 Miles (53 000 km)
²Change the engine oil.
36,000 Miles (58 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the front brake pads and rear brake lin-
ings.
²Flush and replace the engine coolant.
39,000 Miles (62 000 km)
²Change the engine oil.
42,000 Miles (67 000 km)
²Change the engine oil.
²Replace the engine oil filter.
45,000 Miles (72 000 km)
²Change the engine oil.
²Inspect the front brake pads and rear brake lin-
ings.
²Inspect theengine air cleaner element (fil-
ter).Replace as necessary.*
²Adjust the drive belt tension.
²Change the automatic transaxle fluid/filter and
adjust bands.
48,000 Miles (77 000 km)
²Change the engine oil.
²Replace the engine oil filter.
51,000 Miles (82 000 km)
²Change the engine oil.
²Flush and replace the engine coolant.
54,000 Miles (86 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the front brake pads and rear brake lin-
ings.
57,000 Miles (91 000 km)
²Change the engine oil.
60,000 Miles (96 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect thePCV valveand replace if neces-
sary.*
²Lubricate the front suspension lower ball joints.
²Replace the drive belts.
²Replace theengine air cleaner element (fil-
ter).
²Replace theignition cables
²Replace thespark plugs
²Check and replace, if necessary, theengine tim-
ing belton 3.0 liter engines.
²Change the automatic transaxle fluid/filter and
adjust bands.
63,000 Miles (101 000 km)
²Change the engine oil.
²Inspect the front brake pads and rear brake lin-
ings.
66,000 Miles (106 000 km)
²Change the engine oil.
²Replace the engine oil filter.
PLLUBRICATION AND MAINTENANCE 0 - 5
SPECIFICATIONS (Continued)

69,000 Miles (110 000 km)
²Change the engine oil.
72,000 Miles (115 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the front brake pads and rear brake lin-
ings.
75,000 Miles (120 000 km)
²Change the engine oil.
²Adjust the drive belt tension.
²Inspect theengine air cleaner element (fil-
ter)and replace as necessary.*
²Change the automatic transaxle fluid/filter and
adjust bands.
78,000 Miles (125 000 km)
²Change the engine oil.
²Replace the engine oil filter.
81,000 Miles (130 000 km)
²Change the engine oil.
²Flush and replace the engine coolant.
²Inspect the front brake pads and rear brake lin-
ings.
84,000 Miles (134 000 km)
²Change the engine oil.
²Replace the engine oil filter.
87,000 Miles (139 000 km)
²Change the engine oil.
90,000 Miles (144 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect front brake pads and rear brake linings
²Check thePCV valveand replace if necessary.
Not required if previously changed.*
²Lubricate the front suspension lower ball joint.
²Replace theengine air cleaner element (fil-
ter).²Replace thespark plugs
²Change the automatic transaxle fluid/filter and
adjust the bands.
93,000 Miles (149 000 km)
²Change the engine oil.
96,000 Miles (154 000 km)
²Change the engine oil.
²Replace the engine oil filter.
99,000 Miles (158 000 km)
²Change the engine oil.
²Inspect the front brake pads and rear brake lin-
ings.
102,000 Miles (163 000 km)
²Change the engine oil.
²Replace the engine oil filter.
105,000 Miles (168 000 km)
²Replace theengine timing belt.
²Change the engine oil.
²Adjust the drive belt tension.
²Inspect theengine air cleaner element (fil-
ter)and replace as necessary.*
²Change the automatic transaxle fluid/filter and
adjust the bands.
²Flush and replace the engine coolant.
* This maintenance is recommended by Daimler-
Chrysler Corporation to the owner but is not
required to maintain the emissions warranty.
NOTE: Operating the vehicle more than 50% in
heavy traffic during hot weather, above 90É F (32É
C), using vehicle for police, taxi, limousine type
operation or trailer towing require the more fre-
quent transaxle service noted in Schedule ± B. Per-
form these services if vehicle usually operate under
these conditions.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
0 - 6 LUBRICATION AND MAINTENANCEPL
SPECIFICATIONS (Continued)

JUMP STARTING, TOWING, AND HOISTING
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
JUMP STARTING PROCEDURE...............7
TOWING RECOMMENDATIONS...............7
HOISTING RECOMMENDATIONS.............7SERVICE PROCEDURES
JUMP STARTING PROCEDURE...............7
TOWING RECOMMENDATIONS...............8
HOISTING RECOMMENDATIONS.............9
DESCRIPTION AND OPERATION
JUMP STARTING PROCEDURE
Describes the procedure for starting a disable vehi-
cle.
TOWING RECOMMENDATIONS
Describes the recommended towing procedures.
HOISTING RECOMMENDATIONS
Describes the location of hoisting and jacking
points so that the vehicle can be lifted by a floor jack
or hoist.
SERVICE PROCEDURES
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT
JUMP START A FROZEN BATTERY, PERSONAL
INJURY CAN RESULT. DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR. DO NOT JUMP
START A VEHICLE WHEN THE BATTERY FLUID IS
BELOW THE TOP OF LEAD PLATES. DO NOT
ALLOW JUMPER CABLE CLAMPS TO TOUCH
EACH OTHER WHEN CONNECTED TO A BOOSTER
SOURCE. DO NOT USE OPEN FLAME NEAR BAT-
TERY. REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT. WHEN
USING A HIGH OUTPUT BOOSTING DEVICE, DO
NOT ALLOW BATTERY VOLTAGE TO EXCEED 16
VOLTS. REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 1).
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
PLLUBRICATION AND MAINTENANCE 0 - 7