DODGE NEON Shop Manual 1994-1999

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🏷️ Basic Information Identification Make: Dodge Model: Neon Model Years Covered: 1994, 1995, 1996, 1997, 1998, 1999 Codes Chassis Codes: PG (First Generation) 👋 Introduction Market Position Segment: Compact Car...

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类型: Car

斯库: 406755

标签: 1994 1995 1996 1997 1998 1999 Car Cars Dodge Misc NEON

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Model Years Covered:

1994, 1995, 1996, 1997, 1998, 1999

Codes

Chassis Codes:

PG (First Generation)

👋 Introduction

Market Position

Segment:

Compact Car

Target Audience:

Budget-conscious buyers, first-time car owners, performance enthusiasts (with 2.0L DOHC engines).

Competitive Analysis

Key Competitors:

Honda Civic, Toyota Corolla, Ford Escort, Chevrolet Cavalier, Nissan Sentra.

Key Features

Platform:

Chrysler JA platform, shared with Chrysler Cirrus and Plymouth Breeze.

Design Philosophy:

Affordable, sporty design with a focus on European styling influences.

Powertrain Options:

Distinctive for offering Chrysler's in-house engineered 2.0L engines, providing competitive performance for its class.

📋 Manual Details

Coverage Areas

Coverage Type:

Comprehensive Service and Repair

Page Count

Estimated Page Count:

Varies by specific system, but designed for in-depth coverage of all major repair and maintenance tasks. Typically over 2000 pages for a complete factory service manual equivalent.

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine:

2.0L SOHC (420A) and DOHC (AGS), including diagnostics, repair, overhaul, and component testing.

Transmission:

Manual (Getrag A525, Chrysler A568) and Automatic (Chrysler 30R, 31TE), including removal, installation, and internal/external adjustments.

Brakes:

Front Disc, Rear Drum and Rear Disc options, ABS systems, hydraulic components, and parking brake.

Suspension:

Front MacPherson struts, rear multi-link beam axle, wheel alignment specifications, component replacement.

Steering:

Power rack and pinion, steering column, linkages, and hydraulic system components.

Electrical:

Complete wiring diagrams, fuse and relay locations, lighting systems, power accessories, charging system, ignition system, starting system, diagnostic procedures for ECUs and sensors.

HVAC:

Heating, Ventilation, and Air Conditioning system diagnosis, refrigerant handling, component replacement.

Body:

Exterior and interior trim, doors, windows, glass replacement, body panel repair, convertible top mechanisms (where applicable).

Procedures Included

Maintenance:

Scheduled maintenance intervals, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, spark plug replacement, belt inspections and replacement.

Troubleshooting:

Systematic diagnostic flowcharts for common and uncommon drivability issues, electrical faults, and mechanical failures.

Repair:

Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation for all major vehicle systems.

Diagnostics:

OBD-I and OBD-II system diagnostics, trouble code interpretation, sensor testing, actuator testing, ECU relearning procedures.

Technical Specifications:

Torque specifications for all fasteners, engine clearances, valve lash, timing settings, wheel alignment angles, fluid capacities, diagnostic parameters.

Technical Depth

Depth:

Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Covers basic maintenance to complete engine and transmission overhauls.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Print Quality

Quality:

High-resolution scans of original factory service manuals, ensuring clarity of text and diagrams. Printable.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

Searchability

Text Search:

Searchable PDF content for quick access to specific topics and keywords.

Compatibility

Device Compatibility:

PC, Mac, Tablets, and Smartphones

⚙️ Engine Specifications

Primary Engine

Engine 1 Code:

Engine 1 Type:

2.0L SOHC (Single Overhead Cam) Inline-4

Engine 1 Displacement:

1996 cc (121.8 cu in)

Engine 1 Bore X Stroke:

87.6 mm x 83.0 mm

Engine 1 Compression Ratio:

9.4:1

Engine 1 Horsepower:

116 hp @ 5500 rpm

Engine 1 Torque:

124 lb-ft @ 3750 rpm

Secondary Engine

Engine 2 Code:

AGS (Optional for ACR and some SE/ES trims)

Engine 2 Type:

2.0L DOHC (Double Overhead Cam) Inline-4 (Chrysler 4G63 derivative)

Engine 2 Displacement:

1997 cc (121.9 cu in)

Engine 2 Compression Ratio:

10.0:1

Engine 2 Horsepower:

132 hp @ 6000 rpm

Engine 2 Torque:

130 lb-ft @ 4500 rpm

Fuel System

Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 Octane minimum recommended)

Ignition System

Ignition Type:

Distributorless Ignition System (DIS) with coil packs

Cooling System

Coolant Type:

Chrysler Mopar Antifreeze/Coolant (ethylene glycol-based, OAT or HOAT type)

Coolant Capacity:

Approximately 5.7 US quarts (5.4 L) for 420A engine with standard heater.

🔧 Transmission

Standard

Transmission 1 Type:

5-Speed Manual (Getrag A525)

Transmission 1 Fluid Type:

Chrysler Manual Transmission Fluid (MS-9224) or equivalent GL-3/GL-4 gear oil

Optional

Transmission 2 Type:

4-Speed Automatic (Chrysler 30R / 31TE)

Transmission 2 Fluid Type:

ATF+3 (MS-9225) or ATF+4 (MS-9602) recommended for later models if compatible

Features

Clutch Type:

Dry single plate, hydraulically actuated (for manual transmission)

📐 Dimensions

Exterior

Length:

162.8 inches (4135 mm)

Width:

67.4 inches (1712 mm)

Height:

53.0 inches (1346 mm)

Wheelbase:

97.2 inches (2469 mm)

Front Track:

57.5 inches (1460 mm)

Rear Track:

57.6 inches (1463 mm)

Weights

Curb Weight Min:

Approx. 2700 lbs (1225 kg)

Curb Weight Max:

Approx. 2900 lbs (1315 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 3800 lbs (1724 kg)

Cargo

Trunk Volume:

Approx. 12.5 cu ft (0.35 m³) (Coupe/Sedan)

Convertible Trunk Volume:

Approx. 5.0 cu ft (0.14 m³) with top down

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

4-Star (for Coupes, 1997 model year)

IIHS Side Impact Rating:

Acceptable (for 1997 models with side airbags, though side airbags were rare)

Active Features

Available Anti-lock Braking System (ABS) on front wheels (standard on some trims later in production).

Passive Features

Airbags:

Driver and passenger front airbags standard. Optional side airbags available on select models.

Seatbelts:

3-point front and rear seat belts. Driver and front passenger pretensioners.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player, optional CD player available on higher trims.

Display:

Basic analog gauge cluster with integrated digital odometer and trip meter. No central infotainment screen.

Driver Assistance

Cruise Control:

Optional on most models, standard on higher trims.

Connectivity

Connectivity Features:

Limited to basic power accessories. No Bluetooth or USB connectivity from the factory.

🔧 Maintenance

Service Intervals

Engine Oil Change Interval:

Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for specific recommendations).

Engine Oil Filter Replacement:

With every oil change.

Engine Coolant Flush Interval:

Every 30,000 miles or 2-3 years (using recommended coolant type).

Spark Plug Replacement Interval:

Approx. 60,000-100,000 miles for platinum or iridium plugs, depending on type installed.

Timing Belt Replacement Interval:

70,000-100,000 miles for 420A SOHC engines. Timing chain for DOHC (AGS) engines, generally maintenance-free unless issues arise.

Fluid Specifications

Engine Oil Viscosity:

SAE 5W-30 (most common specification for both engines)

Brake Fluid Type:

DOT 3 or DOT 4.

Power Steering Fluid Type:

ATF+3 or equivalent power steering fluid meeting Chrysler MS-4176.

Known Issues

Common Issue 1:

Oil leaks from valve cover gasket and oil pan gasket due to age and material degradation.

Common Issue 2:

Cracked exhaust manifold on 420A engines, leading to exhaust leaks and ticking noises.

Common Issue 3:

Cooling system issues: Leaking hoses, radiator failures, water pump leaks, and clogged heater cores.

Common Issue 4:

Transmission issues: Clutch wear on manual transmissions, occasional solenoid issues or torque converter problems on automatics.

Common Issue 5:

Electrical gremlins: Faulty door lock actuators, window regulators, and issues with the instrument cluster illumination.

Common Issue 6:

Suspension wear: Worn ball joints, tie rod ends, and strut mounts, leading to noise and poor handling.

📚 Vehicle History

Brand Heritage

Brand Origin:

Dodge is an American brand, historically known for performance and muscle cars, later expanding into mainstream and compact segments.

Model Evolution

First Generation Introduction:

Introduced for the 1995 model year as a replacement for the Dodge Omni/Plymouth Horizon.

Design Influences:

Styled with input from Chrysler's European design studio, giving it a more contemporary, rounded look compared to previous Dodge compacts.

Body Styles:

Offered as a 2-door coupe, 4-door sedan, and a 2-door convertible (produced by American Specialty Cars - ASC).

Performance Variants:

Dodge Neon ACR (American Club Racer) offered enhanced suspension and engine tuning for motorsport enthusiasts. High Output (HO) engine variant for SE/ES trims later in the generation.

Production

Manufacturing Locations:

Belvidere Assembly Plant, Illinois, USA.

Production Years:

1994-1999 (First Generation)

🏆 Awards & Recognition

Recognitions

Automotive Press Awards:

Named to Car and Driver's Ten Best list for 1995, highlighting its value and sporty driving dynamics.

Value Proposition:

Widely recognized for its strong price-to-performance ratio and affordable ownership costs.