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Dodge Neon 1997 Factory Service Repair Manual

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$16.99
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$16.99
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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:...
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Dodge Neon 1997 Factory Service Repair Manual
🏷️ 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)
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
ABS:
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.
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