Dodge Neon 1997 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Neon Year: 1997 Codes Platform Code: PG (First Generation) Chassis Codes: DB1 (Coupe), DB2 (Sedan) 👋 Introduction Market Position Segment: Compact Car Positioning: Affordable, sporty compact car designed to compete with Japanese and European rivals. Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Ford Escort, Chevrolet Cavalier, Mazda Protege. Key Features Design Philosophy: Cab-forward design, spacious interior for its class, agile handling, driver-focused cockpit. Value Proposition: Offered a good balance of performance, features, and affordability, particularly in its sportier trims. 📋 Manual Details Coverage Areas Primary Coverage: North America Secondary Coverage: Global (where applicable) Page Count Estimated Pages: 1000+ Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: All major engine systems including: Engine Mechanical, Cooling System, Lubrication System, Fuel System, Emission Control System, Ignition System, Starting System, Charging System, Engine Control System (PCM). Transmission: Manual Transmission (e.g., A520, NV3500) and Automatic Transmission (e.g., A604, Ultradrive) including: Clutch, Gearbox, Torque Converter, Valve Body, Shift Control, Hydraulic System. Drivetrain: Front Wheel Drive (FWD) system including: Drive Axles, CV Joints, Bearings, Differential. Brakes: Front and Rear Brake Systems (Disc/Drum), Anti-lock Braking System (ABS) components, Hydraulic lines, Master Cylinder, Calipers, Rotors, Pads, Parking Brake. Suspension Steering: Front and Rear Suspension (MacPherson Strut front, Twist Beam rear), Shock Absorbers, Springs, Control Arms, Ball Joints, Wheel Bearings, Power Steering System, Steering Gear, Tie Rods. Electrical: Complete Electrical System: Battery, Charging System, Starting System, Lighting System (Headlamps, Tail Lamps, Interior), Fuses, Relays, Wiring Diagrams, Body Control Modules (BCM), Powertrain Control Modules (PCM). Body Interior: Body Exterior: Panels, Doors, Hood, Trunk Lid, Bumpers, Glass, Seals. Interior: Seats, Upholstery, Dashboard, Trim Panels, HVAC System (Heating, Ventilation, Air Conditioning), Restraint Systems (Airbags). HVAC: Air Conditioning Compressor, Condenser, Evaporator, Blower Motor, Heater Core, Controls, Refrigerant Charge and Service. Restraint Systems: Airbag System Components, SRS Module, Impact Sensors, Occupant Classification System. Procedures Included General Maintenance: Oil Changes, Fluid Checks and Replacements, Filter Replacements (Oil, Air, Fuel, Cabin), Spark Plug Replacement, Belt Inspection and Replacement, Tire Rotation and Pressure Checks. Engine Repair: Engine Overhaul, Cylinder Head Removal/Installation, Piston/Connecting Rod Service, Crankshaft Service, Valve Timing Adjustment, Component Replacement (e.g., Water Pump, Oil Pump, Alternator, Starter). Transmission Service: Transmission Fluid Change, Clutch Replacement, Clutch Adjustment, Transmission Removal/Installation, Torque Converter Replacement, Internal Transmission Repair. Brake Service: Brake Pad Replacement, Rotor Replacement, Brake Caliper Service, Brake Fluid Flush and Bleed, Parking Brake Adjustment, ABS Component Diagnosis and Replacement. Suspension Steering Repair: Strut Replacement, Shock Absorber Replacement, Control Arm Bushing Replacement, Ball Joint Replacement, Tie Rod End Replacement, Wheel Bearing Replacement, Power Steering Pump Service, Steering Rack Service. Electrical Diagnostics: Troubleshooting electrical faults using wiring diagrams, Component Testing (e.g., Sensors, Actuators, Relays), Fuse/Circuit Breaker Diagnosis, Battery and Charging System Testing. HVAC Repair: Refrigerant System Service, Compressor Replacement, Evaporator/Condenser Cleaning and Replacement, Blower Motor Replacement, Heater Core Replacement, Blend Door Actuator Repair. Bodywork Repair: Panel alignment, Door mechanism repair, Glass replacement, Seal replacement, Bumper repair/replacement. Restraint System Service: SRS Module Replacement, Airbag Sensor Replacement, Airbag Module Replacement (with appropriate safety precautions). Troubleshooting Guides: Detailed diagnostic procedures for common and uncommon faults, symptom-based troubleshooting charts, diagnostic trouble codes (DTCs) and their meanings. Technical Depth Diagnostic Capabilities: Advanced diagnostics, including OBD-II data interpretation, sensor readings, actuator testing, and electrical system tracing. Rebuild Procedures: Comprehensive engine and transmission rebuild procedures, including disassembly, cleaning, inspection, measurement, and reassembly with specifications. Specifications Data: In-depth technical specifications for all components, including torque values, clearances, fluid capacities, electrical resistance, and tolerances. Wiring Diagrams: Detailed, high-resolution electrical wiring diagrams for all vehicle systems, color-coded for clarity. 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable text PDF for easy navigation and printing. Searchability: Fully searchable text content. Print Quality Print Readability: Designed for clear printing of diagrams, charts, and text. Binding Type Binding: Not Applicable (Digital PDF Download) Paper Type Paper Type: Not Applicable (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Code: 1.8L SOHC I4 (2H) Engine Family: Chrysler/Dodge/Plymouth Emergency Vehicle Engine (EVE) Displacement: 1.8 Liters (1806 cc) Performance Horsepower: 116 hp @ 6000 RPM (approx.) Torque: 114 lb-ft @ 4500 RPM (approx.) Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPFI) Fuel Type: Unleaded Gasoline Engine Mechanical Bore X Stroke: 87.0 mm x 85.0 mm (approx.) Compression Ratio: 9.1:1 (approx.) Valvetrain: Single Overhead Camshaft (SOHC), 2 valves per cylinder (16 valves total) Block Material: Aluminum Alloy Head Material: Aluminum Alloy Cooling System Coolant Type: Mopar OAT (Orange) Antifreeze/Coolant or equivalent Coolant Capacity: 6.7 Liters (7.1 Quarts) (approx.) Lubrication System Oil Type: SAE 5W-30 API SJ or ILSAC GF-2 Oil Capacity: 4.0 Liters (4.2 Quarts) with filter change (approx.) Oil Filter Part Number: Mopar: MO-090, Fram: PH3792, Wix: 51515 🔧 Transmission Standard Type: 5-Speed Manual Transmission (A520) Optional Type: 4-Speed Automatic Transmission (A604 Ultradrive)...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Year:

Codes

Platform Code:

PG (First Generation)

Chassis Codes:

DB1 (Coupe), DB2 (Sedan)

👋 Introduction

Market Position

Segment:

Compact Car

Positioning:

Affordable, sporty compact car designed to compete with Japanese and European rivals.

Competitive Analysis

Key Competitors:

Honda Civic, Toyota Corolla, Ford Escort, Chevrolet Cavalier, Mazda Protege.

Key Features

Design Philosophy:

Cab-forward design, spacious interior for its class, agile handling, driver-focused cockpit.

Value Proposition:

Offered a good balance of performance, features, and affordability, particularly in its sportier trims.

📋 Manual Details

Coverage Areas

Primary Coverage:

North America

Secondary Coverage:

Global (where applicable)

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

All major engine systems including: Engine Mechanical, Cooling System, Lubrication System, Fuel System, Emission Control System, Ignition System, Starting System, Charging System, Engine Control System (PCM).

Transmission:

Manual Transmission (e.g., A520, NV3500) and Automatic Transmission (e.g., A604, Ultradrive) including: Clutch, Gearbox, Torque Converter, Valve Body, Shift Control, Hydraulic System.

Drivetrain:

Front Wheel Drive (FWD) system including: Drive Axles, CV Joints, Bearings, Differential.

Brakes:

Front and Rear Brake Systems (Disc/Drum), Anti-lock Braking System (ABS) components, Hydraulic lines, Master Cylinder, Calipers, Rotors, Pads, Parking Brake.

Suspension Steering:

Front and Rear Suspension (MacPherson Strut front, Twist Beam rear), Shock Absorbers, Springs, Control Arms, Ball Joints, Wheel Bearings, Power Steering System, Steering Gear, Tie Rods.

Electrical:

Complete Electrical System: Battery, Charging System, Starting System, Lighting System (Headlamps, Tail Lamps, Interior), Fuses, Relays, Wiring Diagrams, Body Control Modules (BCM), Powertrain Control Modules (PCM).

Body Interior:

Body Exterior: Panels, Doors, Hood, Trunk Lid, Bumpers, Glass, Seals. Interior: Seats, Upholstery, Dashboard, Trim Panels, HVAC System (Heating, Ventilation, Air Conditioning), Restraint Systems (Airbags).

HVAC:

Air Conditioning Compressor, Condenser, Evaporator, Blower Motor, Heater Core, Controls, Refrigerant Charge and Service.

Restraint Systems:

Airbag System Components, SRS Module, Impact Sensors, Occupant Classification System.

Procedures Included

General Maintenance:

Oil Changes, Fluid Checks and Replacements, Filter Replacements (Oil, Air, Fuel, Cabin), Spark Plug Replacement, Belt Inspection and Replacement, Tire Rotation and Pressure Checks.

Engine Repair:

Engine Overhaul, Cylinder Head Removal/Installation, Piston/Connecting Rod Service, Crankshaft Service, Valve Timing Adjustment, Component Replacement (e.g., Water Pump, Oil Pump, Alternator, Starter).

Transmission Service:

Transmission Fluid Change, Clutch Replacement, Clutch Adjustment, Transmission Removal/Installation, Torque Converter Replacement, Internal Transmission Repair.

Brake Service:

Brake Pad Replacement, Rotor Replacement, Brake Caliper Service, Brake Fluid Flush and Bleed, Parking Brake Adjustment, ABS Component Diagnosis and Replacement.

Suspension Steering Repair:

Strut Replacement, Shock Absorber Replacement, Control Arm Bushing Replacement, Ball Joint Replacement, Tie Rod End Replacement, Wheel Bearing Replacement, Power Steering Pump Service, Steering Rack Service.

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams, Component Testing (e.g., Sensors, Actuators, Relays), Fuse/Circuit Breaker Diagnosis, Battery and Charging System Testing.

HVAC Repair:

Refrigerant System Service, Compressor Replacement, Evaporator/Condenser Cleaning and Replacement, Blower Motor Replacement, Heater Core Replacement, Blend Door Actuator Repair.

Bodywork Repair:

Panel alignment, Door mechanism repair, Glass replacement, Seal replacement, Bumper repair/replacement.

Restraint System Service:

SRS Module Replacement, Airbag Sensor Replacement, Airbag Module Replacement (with appropriate safety precautions).

Troubleshooting Guides:

Detailed diagnostic procedures for common and uncommon faults, symptom-based troubleshooting charts, diagnostic trouble codes (DTCs) and their meanings.

Technical Depth

Diagnostic Capabilities:

Advanced diagnostics, including OBD-II data interpretation, sensor readings, actuator testing, and electrical system tracing.

Rebuild Procedures:

Comprehensive engine and transmission rebuild procedures, including disassembly, cleaning, inspection, measurement, and reassembly with specifications.

Specifications Data:

In-depth technical specifications for all components, including torque values, clearances, fluid capacities, electrical resistance, and tolerances.

Wiring Diagrams:

Detailed, high-resolution electrical wiring diagrams for all vehicle systems, color-coded for clarity.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution, searchable text PDF for easy navigation and printing.

Searchability:

Fully searchable text content.

Print Quality

Print Readability:

Designed for clear printing of diagrams, charts, and text.

Binding Type

Binding:

Not Applicable (Digital PDF Download)

Paper Type

Paper Type:

Not Applicable (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

1.8L SOHC I4 (2H)

Engine Family:

Chrysler/Dodge/Plymouth Emergency Vehicle Engine (EVE)

Displacement:

1.8 Liters (1806 cc)

Performance

Horsepower:

116 hp @ 6000 RPM (approx.)

Torque:

114 lb-ft @ 4500 RPM (approx.)

Fuel System

Fuel Delivery:

Multi-Point Fuel Injection (MPFI)

Fuel Type:

Unleaded Gasoline

Engine Mechanical

Bore X Stroke:

87.0 mm x 85.0 mm (approx.)

Compression Ratio:

9.1:1 (approx.)

Valvetrain:

Single Overhead Camshaft (SOHC), 2 valves per cylinder (16 valves total)

Block Material:

Aluminum Alloy

Head Material:

Aluminum Alloy

Cooling System

Coolant Type:

Mopar OAT (Orange) Antifreeze/Coolant or equivalent

Coolant Capacity:

6.7 Liters (7.1 Quarts) (approx.)

Lubrication System

Oil Type:

SAE 5W-30 API SJ or ILSAC GF-2

Oil Capacity:

4.0 Liters (4.2 Quarts) with filter change (approx.)

Oil Filter Part Number:

Mopar: MO-090, Fram: PH3792, Wix: 51515

🔧 Transmission

Standard

Type:

5-Speed Manual Transmission (A520)

Optional

Type:

4-Speed Automatic Transmission (A604 Ultradrive)

Features

Manual Gear Ratios:

Specific ratios detailed in manual, typically around 3.45:1 first gear.

Automatic Features:

Electronically controlled, lock-up torque converter.

Fluid Specifications

Manual Transmission Fluid:

API GL-4, SAE 75W-90 or 80W-90 Gear Oil (specifics vary by transmission model)

Automatic Transmission Fluid:

Chrysler ATF+3 (or Mopar ATF+3/ATF+4)

Fluid Capacity

Automatic Transmission Fluid Capacity:

Approx. 7.5 Liters (7.9 Quarts) for a complete fill.

📐 Dimensions

Exterior

Length:

4407 mm (173.5 in) (Sedan), 4059 mm (159.8 in) (Coupe)

Width:

1699 mm (66.9 in)

Height:

1374 mm (54.1 in) (Coupe), 1394 mm (54.9 in) (Sedan)

Wheelbase:

2644 mm (104.1 in)

Weights

Curb Weight:

1150 - 1250 kg (2535 - 2756 lbs) (approx., varies by trim/body style)

Gross Vehicle Weight Rating:

Varies by model, consult vehicle placard.

Cargo

Trunk Volume:

Approx. 0.37 m³ (13.1 cu ft) (Sedan), Approx. 0.25 m³ (8.8 cu ft) (Coupe)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

4 Stars (1997 Model Year)

NHTSA Frontal Impact Passenger:

4 Stars (1997 Model Year)

IIHS Frontal Offset:

Good (1997 Model Year)

Active Features

Available (Standard on some higher trims, optional on others)

Passive Features

Airbags:

Driver and Passenger Frontal Airbags (Standard)

Seatbelts:

3-point front seat belts with pretensioners, 3-point rear seat belts.

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with cassette player, optional CD player. Basic speaker systems.

Dashboard Layout:

Driver-oriented dashboard with central gauge cluster, easily accessible controls.

Driver Assistance

Cruise Control:

Available on higher trim levels.

Connectivity

OBD Ii:

Standard OBD-II diagnostic port for emissions and engine diagnostics.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles or 6 months, whichever comes first (under normal driving conditions).

Air Filter Replacement:

Every 15,000 miles or 12 months.

Spark Plug Replacement:

Every 100,000 miles (for original equipment platinum plugs).

Coolant Flush:

Every 30,000 miles or 24 months.

Transmission Fluid Change:

Automatic: Every 30,000 miles or 24 months; Manual: Inspect periodically, change as needed.

Timing Belt Replacement:

This engine uses a timing chain, not a belt.

Fluid Specifications

Brake Fluid:

DOT 3 (or DOT 4 for ABS equipped models)

Power Steering Fluid:

Chrysler Power Steering Fluid or Mopar Power Steering Fluid.

Known Issues

Engine:

Head gasket failures (especially on early models), minor oil leaks, some issues with ignition coils.

Transmission:

Automatic transmission (A604) known for potential solenoid issues and torque converter clutch problems. Manual transmissions are generally robust.

Suspension Steering:

Wear on front suspension components (struts, ball joints, control arm bushings), power steering pump whine.

Electrical:

Window regulator failures, issues with power door locks, occasional sensor failures (e.g., crankshaft position sensor).

HVAC:

Blend door actuator failures, AC refrigerant leaks, blower motor resistor issues.

📚 Vehicle History

Brand Heritage

Manufacturer:

Chrysler Corporation (Dodge Brand)

Model Evolution

First Generation:

Launched for the 1995 model year, this generation was innovative for its time, featuring advanced suspension and a spirited character. The 1997 model represents a mid-cycle refresh with minor styling updates and feature enhancements.

Production

Production Years:

1995-2005 (North America)

Manufacturing Locations:

Belvidere, Illinois, USA (Belvidere Assembly Plant)

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

Named to Car and Driver's 10Best list for 1995 and 1996, highlighting its value, performance, and design.

Motor Trend Car Of The Year:

Nominee for Motor Trend Car of the Year.