The Neon 2000-2004

Much of this material is provided courtesy of the friendly folks at Chrysler, who also provided the photographs.

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Quick Overview

Here's what to look for in the new Neon:

• Increased comfort and convenience
• Better pickup in fifth gear, due to a different gear ratio (manual only)
• Much quieter interior
• Elimination of noise from frameless windows and exhaust donut (due to elimination of frameless windows and exhaust donut)
• Better wind, water, and noise sealing
• A little more room inside, a lot more room in the trunk, similar handling and performance
• Better reliability and durability
• Many "standard options" - this car comes pretty well loaded!

Here are some things you won't find:

• A four-speed automatic transmission. The three-speed automatic is being retained, at least for the time being. [This is no longer true - the 2002 models brought in a four-speed automatic]
• A larger or substantially more powerful engine, at least this year [150 horsepower DOHC in 2001, 205 horsepower turbo in 2003]
• A supercharger or turbocharger [until 2003]
• The four-inch-shorter wheelbase previously rumored. Though DaimlerChrysler (DC) has not told us anything about the uses of the 1.4 and 1.6 liter engines developed in conjunction with Rover, it is possible that there might be a short-wheelbase export Neon planned which would use these engines. We have suspected that a minicar might be in the works but haven't heard a single rumor about one. We frankly don't know.
• The goofy climate controls are still intact... which means that roughly half of all Neon owners will keep their air conditioners active all year without realizing it.

The Second Generation Neon - Overview

With the second generation, Chrysler sought to address design problems of the first generation, to make the car more comfortable, and to keep the handling and acceleration of the first generation intact. It was designed "with substance," to feel solid, provide "unexpected delights," yet stay fun to drive.

In short, the second generation has substantially reduced noise, vibration, and harshness, a larger interior and much larger trunk, and in general a higher quality feel. At the same time, the two major problems of the Neon, frameless windows and the noisy exhaust donut, were eliminated.

• Substantially reduced noise, vibration, and harshness.
• Smoother, more controlled ride
• Maintained agility, driving fun of first-generation Neon
• Increased overall quality yet increased manufacturing efficiencies
• More features for increased value
• An inherently more robust, durable design
• A manufacturing process designed for easier assembly

Design Process

Goals of the design process were to address design issues (such as the troublesome frameless windows), and to increase the use of technology (such as three-dimensional computer modeling), electronic linking of designers, engineers, suppliers, and manufacturing plants, and virtual reality. The benefits of these technologies include increased quality, higher precision, reduced trial and error, shortened development time and lower cost, and computerized crash testing.

This time around, Chrysler is claiming to have conducted extensive endurance testing worldwide, along with race course testing.

Suppliers were involved earlier in the design process, and "hands on" user group evaluations were conducted at all stages of design.

Body Structure

• Bending stiffness increased by 37% from first-generation Neon, torsional stiffness increased by 26% for a smoother, quieter and more controlled ride even under heavy loads
• Framed doors to reduce wind noise, create tighter seal of door to body
• One-piece body-side aperture panels for better fit/finish
• Enhanced sill and center pillar reinforcements
• Strengthened engine compartment structure
• Revised floor pan and instrument panel stiffening beads
• Additional silencers with use of bake-on mastic
• Expandable foam baffles to reduce body noise transmission

Steering/Suspension

• Steering column isolation added to reduce transmission of power steering hydraulic noise
• Redesigned suspension to improve ride quality
• Increased front and rear suspension jounce travel by 15% and 30%, respectively, for smoother ride, less chance of bottoming under heavy loads
• Ride height raised slightly, lower-rate springs and premium shock absorber valving for more comfortable ride
• More effective front sway bar and standard rear sway bar to maintain handling and balance

Brakes

• Improved pedal feel, maintaining low-metallic front linings for quieter operation
• Disc/drum system standard; disc/disc system with ABS, electronic brake proportioning and traction control available
• Teves Mk 20e ABS has less pedal pulsation, and is simpler than the prior system. In addition, it has an electronic system for distributing rear brake pressure to prevent lockup, so it can adjust the rear brake bias to match current conditions. It was first used by DC in the 1999 Grand Cherokee. The optional traction control is actually a very similar system to the ABS: an integrated traction control/ABS system, very similar to that on the 300M. It uses the brake to control spin on the front wheels (from startup to 35 mph, after which it does not activate).

Exhaust

• New exhaust system with larger muffler for quieter engine operation
• Exhaust flex joint replaces sealing ring for lower noise and emissions. In particular, this will address the old "exhaust donut noise."

Engine (2.0 liter)

Webmaster note: This engine will only be available in North America, at least at first, according to the DC press release. We expect that export vehicles will be available with the new Rover/CC 1.6 or the downsized-2.0 (1.8).

Power remains at 132 hp (98 kW) at 5600 rpm, torque increases slightly to 130 ft-lb (177 Nm) at 4600 rpm. (66.2 bhp per liter) - but you seem to get more torque at lower engine speeds, making for faster takeoffs.

• New air induction and intake manifold systems increase peak torque while maintaining peak power and providing quieter engine operation and increased efficiency
• New exhaust manifold, cylinder head cover and timing belt cover for quieter engine operation
• Double Start Override feature disengages starter to prevent double starting
• Four-point engine mount system to reduce idle vibration
• Revised idle speed for better quality and fuel economy
• Increased cooling capacity for engine, transaxle and power steering
• New, dual cycloidal automatic transaxle pump for quieter operation (early 1999 introduction)
• Manual transaxle revised for improved fifth gear performance - presumably this means that pickup is higher in fifth gear (but peak fuel economy is lower).

Exterior

• Rear floor pan lowered 1.0 inch, adding to increased trunk space (13.1 cubic feet vs.11.8)
• Base of windshield moved forward three inches
• New jewel-like headlamps and front fascia design for more unified appearance
• Designed for improved wind and water management
• More pronounced wheel arches for crisper appearance
• Overall length increased 2.6 inches to 174.4; wheelbase increased by 1.0 inch to 105.0; overall width increased by 0.2 inches to 67.4. Track increased 0.6 inch to 58.0
• Ground clearance raised by 0.3 inches to 6.1 to accommodate longer suspension travel
• New rear end and tail lamp design for smoother, refined appearance
• Full-frame doors for reduced wind noise and water leaks, improved door fit and window function
• Triple-sealed doors with heavy-gauge silencers provide highly protective barrier against door cavity and wind noise

Interior

A 60/40 split rear folding seat with head restraints means that you can use an aftermarket child seat (or have two passengers) without losing trunk access. There is easier rear-seat access, as well as more shoulder room (0.9 inches front, 1.5 inches rear), hip room (1.6 inches front, 2.3 inches rear) and rear head room (0.3 inches).The higher front seat (0.5 inches) improves visibility. Cool interior layout despite the lame HVAC controls.

• Increased interior volume (103.4 cu. ft. vs.101.7) for more usable space throughout
• Easier rear seat entry and exit, 60/40 split rear folding seats with head restraints
• Upgraded materials and fabrics, including 'soft touch' on instrument panel and premium door trim
• New taupe interior color
• Revised front seat position (0.5 inch higher, track rearward by 0.4 inch)
• Added contouring for improved appearance, comfort
• More shoulder room (0.9 inch front, 1.5 inch rear)
• More hip room (1.6 inch front, 2.3 inch rear)
• More rear head room (0.3 inch)
• Power switches repositioned on the door for easier access
• All-new instrument panel with circular gauges
• More robust, dimensionally stable instrument panel structure
• Hydroformed steel cross-car beam with magnesium steering column support
• PC ABS base panel, self centering passenger air bag module
• Safety features:
  • Next-generation air bags with less forceful inflators
  • Seat belts with constant force retractors and adjustable turning loops
  • Standard adjustable, locking front head restraints
  • Adjustable, locking rear head restraints (optional)
  • Head impact countermeasures in hard and soft trim

Standard Equipment

• Two major packages, fewer options
• AM/FM cassette, six-speaker sound system
• Self-dimming interior lamps, for those easily impressed by goofy features
• Cup holders: Four that include two can holders, a cup holder with Big Gulp capability and juice boxes. Flip-back armrest for a rear seat cup holder
• Storage: Front compartment for coins, cellular phones, sunglasses. Integrated CD and tissue holder under center armrest. Storage bag hook on back of armrest
• Front map pockets
• Locking glove box with pen and tire gauge holders molded in
• Chime to indicate system malfunctions including a turn signal that is left on
• Battery saver feature turns off the dome light if left on accidentally

Optional Equipment

• Air conditioning
• Four wheel disc brakes and ABS with traction control
• 15-inch wheels and tires
• Aluminum wheels
• Illuminated power lock, window and mirror buttons for easier nighttime driving
• Programmable door locks which automatically engage at 18 mph
• Two-way adjustable, locking head restraints for increased comfort and safety.
• Sentry key, remote keyless entry, new anti-theft alarm - one system available with tamper alert
• Cruise control
• Tilt steering

Environmental Impact

Like the first generation, the second was designed to minimize its environmental impact. Aside from the obvious, an efficient engine (ULEV and LEV where applicable) and aerodynamic design, it uses waterborne paint and molded-in color fascias, asbestos-free brakes, plastic fuel tanks for on-board vapor recovery, and door water shields made from recycled plastic. Even the processes were examined: nearly all containers at the assembly plant are returnable.

Design and Manufacturing

The new Neon cost $703 million, a fairly small amount for a new car (or a redesign). It only took 28 months to develop. A single plant in Belvidere, Illinois (the current main plant) will produce about 260,000 Neons per year. The Toluca plant will presumably be dedicated to other functions.

Specifications