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Chrysler Dodge Neon 1997 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Dodge Neon Year: 1997 Codes Vehicle Platform: PL (First Generation Neon) 👋 Introduction Market Position Segment: Compact Car Target Demographic: Budget-conscious buyers, young drivers, small families. Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Ford Escort, Chevrolet Cavalier, Mitsubishi Mirage. Key Features Design Philosophy: Affordable transportation with a focus on sporty styling and engaging driving dynamics for its class. Platform Shared With: Chrysler Cirrus, Dodge Stratus, Chrysler Sebring Coupe (though mechanicals differ significantly). 📋 Manual Details Coverage Areas General Coverage: Complete factory service and repair information for the 1997 Chrysler/Dodge Neon. Page Count Estimated Pages: 1000+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Printable (Digital format implied by description) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, overhaul, lubrication system, cooling system, fuel system (carbureted and fuel injected), exhaust system, ignition system, starting system, charging system, engine control systems (PCM diagnostics). Transmission Manual: Clutch, manual transmission (gearbox) overhaul, shifting mechanisms, clutch hydraulics. Transmission Automatic: Automatic transmission (transmission name: A577/A580), overhaul, hydraulic control system, torque converter, transmission control module (TCM) diagnostics. Chassis Suspension: Front suspension (struts, control arms, ball joints, tie rods), rear suspension (torsion beam axle, shock absorbers), steering system (power steering, steering column, linkages), wheel alignment specifications. Brakes: Front disc brakes, rear drum brakes (or rear disc on some trims), parking brake system, hydraulic system (master cylinder, brake lines, calipers, wheel cylinders), ABS system (if equipped). Electrical Lighting: 12-volt electrical system, battery, charging system, starting system, lighting (headlights, taillights, interior lights), exterior lighting, interior lighting, fuses, relays, wiring diagrams. Electrical Accessories: Wiper/washer system, horn, power windows, power door locks, mirrors, audio system, instrument cluster, gauges, warning lights, HVAC controls. Body Interior: Body construction, exterior panels, doors, hood, trunk, bumpers, interior trim, seats, dashboard, headliner, carpeting, glass replacement. HVAC: Heating, ventilation, and air conditioning (HVAC) system, A/C compressor, refrigerant, blower motor, heater core, A/C evaporator, controls, diagnostics. Diagnostic Troubleshooting: General diagnostic procedures, symptom-based troubleshooting charts, common fault codes (OBD-I/OBD-II depending on specific engine/PCM), specific component testing. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, air filter replacement, belt inspection and replacement. Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, exhaust system replacement, steering system repairs. Component Replacement: Detailed instructions for replacing virtually all serviceable components, including alternators, starters, water pumps, fuel pumps, radiators, steering racks, brake calipers, etc. Diagnostics And Testing: Step-by-step diagnostic tests for electrical circuits, fuel system pressure testing, ignition system testing, emissions system troubleshooting. Specifications And Tolerances: Torque specifications for all fasteners, engine bearing clearances, piston ring end gap, valve lash specifications, wheel alignment angles. Technical Depth Depth: Comprehensive, from basic scheduled maintenance to full engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures. 📊 Manual Specifications File Format Digital Format: Likely PDF or similar digital format, allowing for targeted printing. Print Quality Printability: Designed to be fully printable, allowing users to print only necessary sections. Binding Type Binding: N/A (Digital format implies user printing and binding) Paper Type Paper Recommendation: Standard printer paper suitable for workshop use. ⚙️ Engine Specifications Primary Engine Engine Code: 2.0L SOHC I4 (Engine Family: Chrysler ECE/ECC) Displacement: 1996 cc (2.0 Liters) Configuration: Inline 4-Cylinder, Single Overhead Camshaft (SOHC) Bore X Stroke: 87.0 mm x 83.0 mm Compression Ratio: 9.4:1 Horsepower: 114 hp @ 5200 rpm Torque: 124 lb-ft @ 3600 rpm Performance Engine Code DOHc: 2.0L DOHC I4 (Engine Family: Chrysler ECB) Displacement DOHc: 1996 cc (2.0 Liters) Configuration DOHc: Inline 4-Cylinder, Double Overhead Camshaft (DOHC) Horsepower DOHc: 145 hp @ 6400 rpm (GT model) Torque DOHc: 135 lb-ft @ 4800 rpm (GT model) Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 octane minimum) Fuel Tank Capacity: 13.0 gallons (49.2 L) 🔧 Transmission Standard Transmission Type Base: 5-speed Manual (A520) Optional Transmission Type Auto: 4-speed Automatic (A577 or A580 depending on engine/market) Features Clutch Type: Dry, single plate, hydraulic actuation (Manual Transmission) Transmission Fluid Manual: API GL-4, SAE 75W-90 Gear Oil (Check specific manual for exact fill) Transmission Fluid Automatic: Chrysler ATF+3 (or equivalent MS-9229 spec fluid) 📐 Dimensions Exterior Wheelbase: 104.4 inches (2652 mm) Length: 170.4 inches (4328 mm) Width: 66.4 inches (1687 mm) Height: 52.4 inches (1331 mm) Track Front: 57.1 inches (1450 mm) Track Rear: 57.7 inches (1465 mm) Ground Clearance: Approximately 5.0 inches (127 mm) - Varies by trim/suspension Weights Curb Weight Min: Approx. 2550 lbs (1157 kg) (Base Sedan) Curb Weight Max: Approx. 2800 lbs (1270 kg) (GT Coupe/Automatic) Cargo Trunk Volume Sedan: Approximately 13.4 cu ft (379 L) Trunk Volume Coupe: Approximately 10.3 cu ft (292 L) 🛡️ Safety Features Ratings NHTSA Driver Frontal Impact: 4 Stars (1997 model year) NHTSA Passenger Frontal Impact: 4 Stars (1997 model year) IIHS Frontal...
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Chrysler Dodge Neon 1997 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Dodge Neon
Year:
1997
Codes
Vehicle Platform:
PL (First Generation Neon)
👋 Introduction
Market Position
Segment:
Compact Car
Target Demographic:
Budget-conscious buyers, young drivers, small families.
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Ford Escort, Chevrolet Cavalier, Mitsubishi Mirage.
Key Features
Design Philosophy:
Affordable transportation with a focus on sporty styling and engaging driving dynamics for its class.
Platform Shared With:
Chrysler Cirrus, Dodge Stratus, Chrysler Sebring Coupe (though mechanicals differ significantly).
📋 Manual Details
Coverage Areas
General Coverage:
Complete factory service and repair information for the 1997 Chrysler/Dodge Neon.
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Printable (Digital format implied by description)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, overhaul, lubrication system, cooling system, fuel system (carbureted and fuel injected), exhaust system, ignition system, starting system, charging system, engine control systems (PCM diagnostics).
Transmission Manual:
Clutch, manual transmission (gearbox) overhaul, shifting mechanisms, clutch hydraulics.
Transmission Automatic:
Automatic transmission (transmission name: A577/A580), overhaul, hydraulic control system, torque converter, transmission control module (TCM) diagnostics.
Chassis Suspension:
Front suspension (struts, control arms, ball joints, tie rods), rear suspension (torsion beam axle, shock absorbers), steering system (power steering, steering column, linkages), wheel alignment specifications.
Brakes:
Front disc brakes, rear drum brakes (or rear disc on some trims), parking brake system, hydraulic system (master cylinder, brake lines, calipers, wheel cylinders), ABS system (if equipped).
Electrical Lighting:
12-volt electrical system, battery, charging system, starting system, lighting (headlights, taillights, interior lights), exterior lighting, interior lighting, fuses, relays, wiring diagrams.
Electrical Accessories:
Wiper/washer system, horn, power windows, power door locks, mirrors, audio system, instrument cluster, gauges, warning lights, HVAC controls.
Body Interior:
Body construction, exterior panels, doors, hood, trunk, bumpers, interior trim, seats, dashboard, headliner, carpeting, glass replacement.
HVAC:
Heating, ventilation, and air conditioning (HVAC) system, A/C compressor, refrigerant, blower motor, heater core, A/C evaporator, controls, diagnostics.
Diagnostic Troubleshooting:
General diagnostic procedures, symptom-based troubleshooting charts, common fault codes (OBD-I/OBD-II depending on specific engine/PCM), specific component testing.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, air filter replacement, belt inspection and replacement.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, exhaust system replacement, steering system repairs.
Component Replacement:
Detailed instructions for replacing virtually all serviceable components, including alternators, starters, water pumps, fuel pumps, radiators, steering racks, brake calipers, etc.
Diagnostics And Testing:
Step-by-step diagnostic tests for electrical circuits, fuel system pressure testing, ignition system testing, emissions system troubleshooting.
Specifications And Tolerances:
Torque specifications for all fasteners, engine bearing clearances, piston ring end gap, valve lash specifications, wheel alignment angles.
Technical Depth
Depth:
Comprehensive, from basic scheduled maintenance to full engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.
📊 Manual Specifications
File Format
Digital Format:
Likely PDF or similar digital format, allowing for targeted printing.
Print Quality
Printability:
Designed to be fully printable, allowing users to print only necessary sections.
Binding Type
Binding:
N/A (Digital format implies user printing and binding)
Paper Type
Paper Recommendation:
Standard printer paper suitable for workshop use.
⚙️ Engine Specifications
Primary Engine
Engine Code:
2.0L SOHC I4 (Engine Family: Chrysler ECE/ECC)
Displacement:
1996 cc (2.0 Liters)
Configuration:
Inline 4-Cylinder, Single Overhead Camshaft (SOHC)
Bore X Stroke:
87.0 mm x 83.0 mm
Compression Ratio:
9.4:1
Horsepower:
114 hp @ 5200 rpm
Torque:
124 lb-ft @ 3600 rpm
Performance
Engine Code DOHc:
2.0L DOHC I4 (Engine Family: Chrysler ECB)
Displacement DOHc:
1996 cc (2.0 Liters)
Configuration DOHc:
Inline 4-Cylinder, Double Overhead Camshaft (DOHC)
Horsepower DOHc:
145 hp @ 6400 rpm (GT model)
Torque DOHc:
135 lb-ft @ 4800 rpm (GT model)
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 octane minimum)
Fuel Tank Capacity:
13.0 gallons (49.2 L)
🔧 Transmission
Standard
Transmission Type Base:
5-speed Manual (A520)
Optional
Transmission Type Auto:
4-speed Automatic (A577 or A580 depending on engine/market)
Features
Clutch Type:
Dry, single plate, hydraulic actuation (Manual Transmission)
Transmission Fluid Manual:
API GL-4, SAE 75W-90 Gear Oil (Check specific manual for exact fill)
Transmission Fluid Automatic:
Chrysler ATF+3 (or equivalent MS-9229 spec fluid)
📐 Dimensions
Exterior
Wheelbase:
104.4 inches (2652 mm)
Length:
170.4 inches (4328 mm)
Width:
66.4 inches (1687 mm)
Height:
52.4 inches (1331 mm)
Track Front:
57.1 inches (1450 mm)
Track Rear:
57.7 inches (1465 mm)
Ground Clearance:
Approximately 5.0 inches (127 mm) - Varies by trim/suspension
Weights
Curb Weight Min:
Approx. 2550 lbs (1157 kg) (Base Sedan)
Curb Weight Max:
Approx. 2800 lbs (1270 kg) (GT Coupe/Automatic)
Cargo
Trunk Volume Sedan:
Approximately 13.4 cu ft (379 L)
Trunk Volume Coupe:
Approximately 10.3 cu ft (292 L)
🛡️ Safety Features
Ratings
NHTSA Driver Frontal Impact:
4 Stars (1997 model year)
NHTSA Passenger Frontal Impact:
4 Stars (1997 model year)
IIHS Frontal Offset:
Acceptable (Good on later revisions/models)
Active Features
ABS:
Optional (Standard on some higher trims or GT models)
Passive Features
Airbags:
Driver and Passenger Airbags (Standard)
Seatbelts:
3-point front seat belts, 3-point rear seat belts (center lap belt for rear middle seat)
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM radio with cassette player, optional CD player. Limited speaker configurations (e.g., 4 speakers standard).
Driver Assistance
ABS Availability:
Optional, not standard across all trims.
Connectivity
Connectivity Features:
None (No integrated Bluetooth, USB, or auxiliary inputs from the factory). Relies on aftermarket solutions.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 miles or 3 months (conventional oil), 7,500 miles or 6 months (synthetic oil - check manual for specific approval)
Air Filter Replacement:
Every 15,000 miles or 12 months
Spark Plug Replacement:
Every 30,000 miles (standard platinum plugs)
Timing Belt Replacement:
Every 60,000 miles or 5 years (critical maintenance item for interference engine)
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 5W-30 (refer to manual for temperature ranges and specific viscosity grades)
Coolant Type:
Chrysler Long Life Antifreeze/Coolant, 50/50 mix with distilled water (Ethylene Glycol based)
Brake Fluid Type:
DOT 3 Hydraulic Brake Fluid
Known Issues
Engine Problems:
Head gasket failures (particularly on early models and SOHC engines), oil leaks, piston slap, noisy lifters.
Transmission Problems:
Automatic transmission hard shifts or failure to shift, clutch wear (manual), synchro issues (manual).
Suspension And Steering:
Worn ball joints and tie rod ends, premature wear of front strut mounts, power steering pump noise or leaks.
Electrical Issues:
Faulty window regulators, power lock actuators, instrument cluster failures, intermittent gauge operation, ignition switch problems.
Body And Chassis:
Rust on rocker panels, wheel wells, and subframes; interior trim pieces becoming loose or rattling.
📚 Vehicle History
Brand Heritage
Brand Origins:
Chrysler Corporation, founded by Walter Chrysler in 1925.
Model Evolution
Introduction Year:
1995 (as a 1995 model year vehicle)
First Generation Years:
1995-1999
Platform Development:
Designed as part of Chrysler's 'Small Car' platform initiative, co-developed with Mitsubishi Motors.
Production
Manufacturing Locations:
Belvidere, Illinois, USA; Brampton, Ontario, Canada.
Sales Performance Overview:
Initially strong sales due to competitive pricing and sporty design, but later plagued by quality concerns and perceived lower build quality compared to Japanese rivals.
🏆 Awards & Recognition
Recognitions
Car And Driver Ten Best:
Named to Car and Driver's Ten Best list for 1995.
Consumer Reports:
Mixed reviews from Consumer Reports, often citing reliability concerns in later years, despite good initial driving impressions.
Certifications
Emissions Compliance:
Designed to meet U.S. Federal emissions standards for 1997 model year. Manual includes detailed emissions diagnostic procedures.
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