DODGE NEON 1999 Service Repair Manual

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LUBRICATION AND MAINTENANCE
CONTENTS
page page
GENERAL INFORMATION................... 1
JUMP STARTING, TOWING AND HOISTING.... 7MAINTENANCE SCHEDULES................ 3
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
CLASSIFICATION OF LUBRICANTS........... 1
FLUID CAPACITIES....................... 2
INTERNATIONAL SYMBOLS................ 1INTRODUCTION......................... 1
PARTS AND LUBRICANT
RECOMMENDATIONS.................... 1
GENERAL INFORMATION
INTRODUCTION
Service and maintenance procedures for compo-
nents and systems listed in Schedule ± A or B can be
found by using the Group Tab Locator index at the
front of this manual. If it is not clear which group
contains the information needed, refer to the index at
the back of this manual.
There are two maintenance schedules that show
proper service based on the conditions that the vehi-
cle is subjected to.
Schedule ±A, lists scheduled maintenance to be
performed when the vehicle is used for general trans-
portation.
Schedule ±B, lists maintenance intervals for vehi-
cles that are operated under the conditions listed at
the beginning of the Maintenance Schedule section.
Use the schedule that best describes your driving
conditions.
Where time and mileage are listed, follow the
interval that occurs first.
PARTS AND LUBRICANT RECOMMENDATIONS
When service is required, Chrysler Corporation
recommends that only Mopartbrand parts, lubri-
cants and chemicals be used. Mopar provides the
best engineered products for servicing Chrysler Cor-
poration vehicles.
INTERNATIONAL SYMBOLS
Chrysler Corporation uses international symbols to
identify engine compartment lubricant and fluid
inspection and fill locations (Fig. 1).
CLASSIFICATION OF LUBRICANTS
Only lubricants that are endorsed by the following
organization should be used to service a Chrysler
Corporation vehicle.
²Society of Automotive Engineers (SAE)
²American Petroleum Institute (API) (Fig. 2)
²National Lubricating Grease Institute (NLGI)
(Fig. 3)
Fig. 1 International Symbols
PLLUBRICATION AND MAINTENANCE 0 - 1

ENGINE OIL
SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. SAE 30 specifies a single viscos-
ity engine oil. Engine oils also have multiple
viscosities. These are specified with a dual SAE vis-
cosity grade which indicates the cold-to-hot tempera-
ture viscosity range.
²SAE 30 = single grade engine oil.
²SAE 10W-30 = multiple grade engine oil.
API QUALITY CLASSIFICATION
The API Service Grade specifies the type of perfor-
mance the engine oil is intended to provide. The API
Service Grade specifications also apply to energy con-
serving engine oils.
Use engine oils that are API Service Certified.
5W-30 and 10W-30 MOPAR engine oils conform to
specifications.
Refer to Group 9, Engine for engine oil specifica-
tion.
GEAR LUBRICANTS
SAE ratings also apply to multiple grade gear
lubricants. In addition, API classification defines the
lubricants usage.
LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 3) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letterªGº. 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.
FLUID CAPACITIES
FUEL TANK
All ..........................47.3 L (12.5 gal.)
ENGINE OIL W/FILTER CHANGE
All...........................4.25 L (4.5 qts.)
ENGINE OIL W/OUT FILTER CHANGE
All............................3.8 L (4.0 qts.)
COOLING SYSTEM
All*.............................6L(6.5 qts.)
*Includes heater and coolant recovery bottle
AUTOMATIC TRANSAXLE
NOTE: Overhaul Fill Capacity with Torque Con-
verter Empty
31TH .........................8.4 L (8.9 qts.)
31 TH (Fleet Vehicles).............8.7 L (9.2 qts.)
MANUAL TRANSAXLE
NV T350.................1.9-2.2 L (4.0-4.6 pts.)
POWER STEERING
All...........................0.95 L (2.0 pts.)
Fig. 2 API Symbol
Fig. 3 NLGI Symbol
0 - 2 LUBRICATION AND MAINTENANCEPL
GENERAL INFORMATION (Continued)

MAINTENANCE SCHEDULES
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 3
SCHEDULE ± A.......................... 3SCHEDULE ± B.......................... 4
UNSCHEDULED INSPECTION............... 3
GENERAL INFORMATION
INTRODUCTION
Service and maintenance procedures for compo-
nents and systems listed in Schedule ± A or B can be
found by using the Group Tab Locator index at the
front of this manual. If it is not clear which group
contains the information needed, refer to the index at
the back of this manual.
There are two maintenance schedules that show
proper service based on the conditions that the vehi-
cle is subjected to. Use the schedule that best
describes these conditions.
Schedule ±A, lists maintenance recommended for
vehicles used for general transportation.
Schedule ±B, lists maintenance recommended for
vehicles used under the following conditions:
²Frequent short trip driving less than 5 miles (8
km)
²Frequent driving in dusty conditions
²Frequent trailer towing
²Extensive idling
²More than 50% of your driving is at sustained
high speeds during hot weather, above 90ÉF (32ÉC)
Where time and mileage are listed, follow the
interval that occurs first.
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.
UNSCHEDULED INSPECTION
At Each Stop For Fuel
²Check engine oil level, add as required.
²Check windshield washer solvent and add if
required.
Once A Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect battery, clean, and tighten terminals as
required.
²Check fluid levels of coolant reservoir, power
steering and automatic transmission and add as
required.
²Check all lights and all other electrical items for
correct operation.
At Each Oil Change
²Inspect exhaust system.
²Inspect brake hoses.
²Inspect the CV joints and front suspension com-
ponents.
²Rotate the tires at each oil change interval
shown on Schedule ± A (7,500 miles) or every other
interval shown on schedule ± B (6,000 miles).
²Check coolant level, hoses and clamps.
²Check the manual transaxle fluid level.
²If the mileage is less than 7,500 miles (12 000
km) yearly, replace the engine oil filter at each oil
change.
SCHEDULE ± A
7,500 Miles (12 000 km) or at 6 months
²Change engine oil.
15,000 Miles (24 000 km) or at 12 months
²Change engine oil.
²Replace engine oil filter.
²Adjust drive belt tension.
22,500 Miles (36 000 km) or at 18 months
²Change engine oil.
²Inspect the front brake pads and rear brake lin-
ings.
30,000 Miles (48 000 km) or at 24 months
²Change engine oil.
²Replace engine oil filter.
²Lubricate front suspension ball joints.
²Adjust drive belt tension.
PLLUBRICATION AND MAINTENANCE 0 - 3

²Replace air cleaner element.
²Replace spark plugs.
²Change automatic transmission fluid.
37,500 Miles (60 000 km) or at 30 months
²Change engine oil.
45,000 Miles (72 000 km) or at 36 months
²Change engine oil.
²Replace engine oil filter.
²Inspect front brake pads and rear brake linings.
²Adjust drive belt tension.
²Flush and replace engine coolant at 36 months,
regardless of mileage.
52,500 Miles (84 000 km) or at 42 months
²Change engine oil.
²Flush and replace engine coolant if not done at
36 months.
60,000 Miles (96 000 km) or at 48 months
²Change engine oil.
²Replace engine oil filter.
²Check and replace, if necessary***, the PCV
valve.**
²Lubricate front suspension upper ball joints.
²Replace drive belts.
²Replace air cleaner element.
²Replace ignition cables.
²Replace spark plugs.
²Change automatic transmission fluid.
67,500 Miles (108 000 km) or at 54 months
²Change engine oil.
²Inspect front brake pads and rear brake linings.
75,000 Miles (120 000 km) or at 60 months
²Change engine oil.
²Replace engine oil filter.
²Adjust drive belt tension.
²Flush and replace engine coolant if it 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 engine oil.
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 engine oil.
²Replace engine oil filter.
²Check and replace, if necessary***, the PCV
valve.**
²Lubricate front suspension upper ball joints.
²Inspect front brake pads and rear brake linings.²Adjust drive belt tension.
²Replace air cleaner air cleaner element.
²Replace spark plugs.
²Change automatic transmission fluid.
97,500 Miles (156 000 km) or at 78 months
²Change engine oil.
105,000 Miles (168 000 km)
²Change engine oil.
²Replace engine oil filter.
²Replace engine timing belt
²Adjust drive belt tension.
SCHEDULE ± B
NOTE: * Follow this schedule if you usually operate
your vehicle under one or more of the following
conditions. Change the automatic transmission
fluid and filter every 15,000 miles (24 000 km) if you
usually operate your vehicle under one of the con-
ditions marked with an *.
3,000 Miles (5 000 km)
²Change engine oil
6,000 Miles (10 000 km)
²Change engine oil
²Replace engine oil filter.
9,000 Miles (14 000 km)
²Change engine oil
²Inspect front brake pads and rear brake lining.
12,000 Miles (19 000 km)
²Change engine oil
²Replace engine oil filter.
15,000 Miles (24 000 km)
²Change engine oil
²Adjust drive belt tension.
²Inspect and replace, if required, the air
cleaner element.
²Change automatic transaxle fluid and filter.
Adjust the bands.*
18,000 Miles (29 000 km)
²Change engine oil
²Replace engine oil filter.
²Inspect front brake pads and rear brake linings.
21,000 Miles (34 000 km)
²Change engine oil
0 - 4 LUBRICATION AND MAINTENANCEPL
GENERAL INFORMATION (Continued)

24,000 Miles (38 000 km)
²Change engine oil
²Replace engine oil filter.
27,000 Miles (43 000 km)
²Change engine oil
²Inspect front brake pads and rear brake linings.
30,000 Miles (48 000 km)
²Change engine oil
²Replace engine oil filter.
²Check and replace, if necessary, the PCV
valve.**
²Lubricate front suspension upper ball joints.
²Adjust drive belt tension.
²Replace air cleaner element.
²Replace spark plugs.
²Change automatic transmission fluid and filter.
Adjust the bands.*
33,000 Miles (53 000 km)
²Change engine oil.
36,000 Miles (58 000 km)
²Change engine oil.
²Replace engine oil filter.
²Flush and replace engine coolant.
²Inspect front brake pads and rear brake linings.
39,000 Miles (62 000 km)
²Change engine oil.
42,000 Miles (67 000 km)
²Change engine oil.
²Replace engine oil filter.
45,000 Miles (72 000 km)
²Change engine oil.
²Inspect front brake pads and rear brake linings.
²Inspect and replace, if necessary, the air
cleaner element.
²Adjust drive belt tension.
²Change automatic transaxle fluid and filter.
Adjust the bands.*
48,000 Miles (77 000 km)
²Change engine oil.
²Replace engine oil filter.
51,000 Miles (82 000 km)
²Change engine oil.
²Flush and replace engine coolant.
54,000 Miles (86 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect front brake pads and rear brake linings.
57,000 Miles (91 000 km)
²Change engine oil.
60,000 Miles (96 000 km)
²Change engine oil.
²Replace engine oil filter.
²Check and replace, if necessary***, the PCV
valve.**
²Lubricate front suspension upper ball joints.
²Replace drive belts.
²Replace air cleaner element.
²Replace ignition cables.
²Replace spark plugs.
²Change automatic transaxle fluid and filter.
Adjust the bands.*
63,000 Miles (101 000 km)
²Change engine oil.
²Inspect front brake pads and rear brake linings.
66,000 Miles (106 000 km)
²Change engine oil.
²Replace engine oil filter.
69,000 Miles (110 000 km)
²Change engine oil.
72,000 Miles (115 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect front brake pads and rear brake linings.
75,000 Miles (120 000 km)
²Change engine oil.
²Adjust drive belt tension.
²Inspect and replace, if necessary, the air
cleaner element.
²Change automatic transaxle fluid and filter.
Adjust the bands.*
78,000 Miles (125 000 km)
²Change engine oil.
²Replace engine oil filter.
81,000 Miles (130 000 km)
²Change engine oil.
²Flush and replace the engine coolant.
²Inspect front brake pads and rear brake linings.
84,000 Miles (134 000 km)
²Change engine oil.
²Replace engine oil filter.
87,000 Miles (139 000 km)
²Change engine oil.
PLLUBRICATION AND MAINTENANCE 0 - 5
GENERAL INFORMATION (Continued)

90,000 Miles (144 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect front brake pads and rear brake linings.
²Check and replace, if necessary***, the PCV
valve.**
²Lubricate front suspension upper ball joints.
²Adjust drive belt tension.
²Replace air cleaner element.
²Replace spark plugs.
²Change automatic transaxle fluid and filter.
Adjust the bands.*
93,000 Miles (149 000 km)
²Change engine oil.
96,000 Miles (154 000 km)
²Change engine oil.
²Replace engine oil filter.
99,000 Miles (158 000 km)
²Change engine oil.
²Inspect front brake pads and rear brake linings.
102,000 Miles (163 000km)
²Change engine oil.
²Replace engine oil filter.
105,000 Miles (168 000km)
²Replace the engine timing belt
²Change engine oil.
²Replace engine oil filter.
²Adjust drive belt tension.
²Inspect and replace, if necessary, the air
cleaner element.
NOTE: **This maintenance is recommended by
Chrysler to the owner but is not required to main-
tain the warranty on the PCV valve.
NOTE: ***This maintenance is not required if the
PCV valve was previously replaced.
0 - 6 LUBRICATION AND MAINTENANCEPL
GENERAL INFORMATION (Continued)

JUMP STARTING, TOWING AND HOISTING
INDEX
page page
SERVICE PROCEDURES
HOISTING RECOMMENDATIONS............ 9JUMP STARTING PROCEDURE.............. 7
TOWING RECOMMENDATIONS.............. 8
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, placethe 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-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
Fig. 1 Jumper Cable Clamp Connections
PLLUBRICATION AND MAINTENANCE 0 - 7

DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING RECOMMENDATIONS
WARNING: DO NOT ALLOW TOWING ATTACH-
MENT DEVICES TO CONTACT THE FUEL TANK OR
LINES, FUEL LEAK CAN RESULT. DO NOT LIFT OR
TOW VEHICLE BY FRONT OR REAR BUMPER, OR
BUMPER ENERGY ABSORBER UNITS. DO NOT
VENTURE UNDER A LIFTED VEHICLE IF NOT SUP-
PORTED PROPERLY ON SAFETY STANDS. DO NOT
ALLOW PASSENGERS TO RIDE IN A TOWED VEHI-
CLE. USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust
system, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle. Do not attach towing device to
front or rear suspension components. Do not
secure vehicle to towing device by the use of front
or rear suspension or steering components.
Remove or secure loose or protruding objects from
a damaged vehicle before towing. Refer to state and
local rules and regulations before towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use of a wheel lift or flat bed towing device (Fig. 2) is
recommended. When using a wheel lift towing device,
be sure the unlifted end of disabled vehicle has at
least 100 mm (4 in.) ground clearance. If minimum
ground clearance cannot be reached, use a towing
dolly. If a flat bed device is used, the approach angle
should not exceed 15 degrees.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels
removed, install lug nuts to retain brake drums or
rotors.
A towed vehicle should be raised until lifted wheels
are a minimum 100 mm (4 in) from the ground. Be
sure there is adequate ground clearance at the oppo-
site end of the vehicle, especially when towing overrough terrain or steep rises in the road. If necessary,
remove the wheels from the lifted end of the vehicle
and lower the vehicle closer to the ground, to
increase the ground clearance at the opposite end of
the vehicle. Install lug nuts on wheel attaching studs
to retain brake drums or rotors.
LOCKED VEHICLE TOWING
When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.
FLAT TOWING WITH TOW BAR
²3-speed automatic transaxle vehicles can be flat
towed at speeds not to exceed 40 km/h (25 mph) for
not more than 25 km (15 miles). The steering column
must be unlocked and gear selector in neutral.
²5-speed manual transaxle vehicles can be flat
towed at any legal highway speed for extended dis-
tances. The gear selector must be in the neutral posi-
tion.
TOWINGÐFRONT WHEEL LIFT
Chrysler Corporation recommends that a vehicle be
towed with the front end lifted, whenever possible.
TOWINGÐREAR WHEEL LIFT
If a vehicle cannot be towed with the front wheels
lifted, the rear wheels can be lifted provided the fol-
lowing guide lines are observed.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
²Unlock steering column and secure steering
wheel in straight ahead position with a clamp device
designed for towing.
²Verify that front drive line and steering compo-
nents are in good condition.
²5-speed manual transaxle vehicles can be towed
at any legal highway speed for extended distances.
The gear selector must be in the neutral position.
²3-speed automatic transaxle vehicles can be
towed at speeds not to exceed 40 km/h (25 mph) for
Fig. 2 Recommended Towing Devices
0 - 8 LUBRICATION AND MAINTENANCEPL
SERVICE PROCEDURES (Continued)

not more than 25 km (15 miles). The gear selector
must be in the neutral position.
HOISTING RECOMMENDATIONS
Refer to Owner's Manual provided with vehicle for
proper emergency jacking procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN THE ENGINE OR REAR SUSPENSION
IS REMOVED FROM A VEHICLE, THE CENTER OF
GRAVITY IS ALTERED MAKING SOME HOISTING
CONDITIONS UNSTABLE. PROPERLY SUPPORT OR
SECURE VEHICLE TO HOISTING DEVICE WHEN
THESE CONDITIONS EXIST.
CAUTION: Do not position hoisting device on sus-
pension components, damage to vehicle can result.
Do not attempt to raise one entire side of the
vehicle by placing a floor jack midway between the
front and rear wheels. This practice may result in
permanent damage to the body.
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a PL vehicle (Fig. 3). Support the vehicle in the
raised position with jack stands.
A floor jack must never be used on any part of the
underbody.
HOIST
A vehicle can be lifted with:
²A single-post, frame-contact hoist.²A twin-post, chassis hoist.
²A ramp-type, drive-on hoist.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly
(Fig. 3).
Fig. 3 Hoisting and Jacking Points
PLLUBRICATION AND MAINTENANCE 0 - 9
SERVICE PROCEDURES (Continued)