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1997 dodge neon service repair manual
1. Welcome to the
1997 Neon
(RHD & LHD)
Interactive Electronic Service Manual!
CLICK ON VEHICLE TO BEGIN
tweddle litho: dom parts cdrom demo 09/96
page 4 <output:1248 ET 01/22/97>
2. GROUP TAB LOCATOR
Introduction
0 Lubrication and Maintenance
2 Suspension
3 Differential and Driveline
5 Brakes
6 Clutch
7 Cooling
8A Battery
8B Starting
8C Charging System
8D Ignition System
8E Instrument Panel and Systems
8F Audio System
8G Horns
8H Vehicle Speed Control System
8J Turn Signal and Flashers
8K Windshield Wipers and Washers
8L Lamps
8M Restraint System
8N Electrically Heated Systems
8P Power Door Locks
8S Power Windows
8T Power Mirrors
8U Chime Warning/Reminder System
8W Wiring Diagrams
9 Engines
11 Exhaust System and Intake Manifold
13 Frame and Bumpers
14 Fuel System
19 Steering
21 Transaxle
22 Tires and Wheels
23 Body
24 Heating and Air Conditioning
25 Emission Control Systems
3. INTRODUCTION
CONTENTS
page page
GENERAL INFORMATION
BODY CODE EMBOSS . . . . . . . . . . . . . . . . . . . 2
FASTENER IDENTIFICATION . . . . . . . . . . . . . . . 4
INTERNATIONAL VEHICLE CONTROL AND
DISPLAY SYMBOLS . . . . . . . . . . . . . . . . . . . . 3
METRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 7
STANDARD BODY DIMENSIONS . . . . . . . . . . . . 3
TORQUE REFERENCES . . . . . . . . . . . . . . . . . 10
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . 1
VEHICLE SAFETY CERTIFICATION LABEL . . . . 2
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER
The Vehicle Identification Number (VIN) is located
on the upper left corner of the instrument panel,
near the left A-Pillar. The VIN consists of 17 charac-
ters in a combination of letters and numbers that
provide specific information about the vehicle (Fig.
1). Refer to VIN Code Decoding Chart.
To protect the consumer from theft and possible
fraud the manufacturer is required to include a
Check Digit at the ninth position of the Vehicle Iden-
tification Number. The check digit is used by the
manufacturer and government agencies to verify the
authenticity of the vehicle and official documenta-
tion. The formula to use the check digit is not
released to the general public.
Fig. 1 Vehicle Identification Number
INSTRUMENT
PANEL A-PILLAR
VIN LOCATION
PL INTRODUCTION 1
4. VEHICLE SAFETY CERTIFICATION LABEL
A vehicle safety certification label (Fig. 2) is
attached to the rear facing of the driver’s door. This
label indicates date of manufacture (month and
year), Gross Vehicle Weight Rating (GVWR), Gross
Axle Weight Rating (GAWR) front, Gross Axle Weight
Rating (GAWR) rear and the Vehicle Identification
Number (VIN). The Month, Day and Hour of manu-
facture is also included.
All communications or inquiries regarding the
vehicle should include the Month-Day-Hour and
Vehicle Identification Number.
BODY CODE EMBOSS
The Body Code Emboss is located in the engine
compartment on the front of the right strut tower.
There are two lines of information in the body code
emboss.
BODY CODE EMBOSS LINE 1
Line 1 contains the Vehicle Identification Number
(VIN). Refer to Vehicle Identification Number (VIN)
paragraph for proper breakdown of VIN code.
BODY CODE EMBOSS LINE 2
DIGITS 1-3 —Paint Code
Refer to Group 23, Body for paint information.
DIGITS 4-7 —Trim Code
Refer to Parts Catalog for more information.
DIGITS 5-10 —Open
DIGITS 11-14 —Vehicle Order Number
VIN CODE DECODING
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1= United states
3= Mexico
2 Make B= Dodge
P= Plymouth
3 Vehicle Type 3 = Passenger Car
4 Pass. Safety E = Active Restraints, Driver &
Passenger Airbags
5 Car Line S = Neon / Neon Sport (sold in
U.S./Canada)
6= Neon/Neon Sport (sold in Mexico)
6 Series 2 = Low Line
4 = High Line
6 = Sport
7 Body Style 2 = 2 Door Pillared Hardtop
7 = 4 Door Pillared Hardtop
8 Engine C = 2.0L 4 Cyl. 16V
Y = 2.0L 4 Cyl. DOHC
9 Check Digit
10 Model Year V = 1997
11 Assembly Plant D = Belvidere
T = Toluca
12 Thru 17 Vehicle Build Sequence Assembly Sequence
Fig. 2 Vehicle Safety Certification Label
2 INTRODUCTION PL
GENERAL INFORMATION (Continued)
5. STANDARD BODY DIMENSIONS
INTERNATIONAL VEHICLE CONTROL AND DISPLAY
SYMBOLS
INTERNATIONAL VEHICLE CONTROL AND
DISPLAY SYMBOLS
The graphic symbols illustrated in the following
chart (Fig. 3) are used to identify various instrument
controls. The symbols correspond to the controls and
displays that are located on the instrument panel.
INTERIOR DIMENSIONS
CAR
BODY
STYLE
HEAD ROOM LEG ROOM SHOULDER ROOM HIP ROOM
FRONT REAR FRONT REAR FRONT REAR FRONT REAR
PL PL-42 1005 mm 928 mm 1080 mm 891 mm 1333 mm 1329 mm 1290 mm 1286 mm
39.6 in. 36.5 in. 42.5 in. 35.1 in. 52.5 in. 52.3 in. 50.8 in. 50.6 in.
PL PL-22 1005 mm 928 mm 1080 mm 891 mm 1321 mm 1391 mm 1277 mm 1369 mm
39.6 in. 36.5 in. 42.5 in. 35.1 in. 52.0 in. 54.7 in. 50.3 in. 53.9 in.
EXTERIOR DIMENSIONS
CAR
BODY
STYLE
WHEEL
BASE
FRONT
TRACK
REAR
TRACK
OVERALL
LENGTH
OVERALL
WIDTH
OVERALL
HEIGHT
MM/IN. MM/IN. MM/IN. MM/IN. MM/IN. MM/IN.
PL PL-42 2642/104 1458/57.4 1458/57.4 4364/171.8 1708/67.2 1395/54.9
PL PL-22 2642/104 1458/57.4 1458/57.4 4364/171.8 1711/67.4 1395/54.9
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
HIGH BEAM
FOG LIGHTS
HEADLIGHTS, PARKING
LIGHTS, PANEL LIGHTS
TURN SIGNAL
HAZARD WARNING
WINDSHIELD WASHER
WINDSHIELD WIPER
WINDSHIELD WIPER AND
WASHER
WINDSCREEN DEMISTING
AND DEFROSTING
VENTILATING FAN
REAR WINDOW DEFOGGER
REAR WINDOW WIPER
REAR WINDOW WASHER
FUEL
ENGINE COOLANT TEMPER-
ATURE
BATTERY CHARGING CON-
DITION
ENGINE OIL
SEAT BELT
BRAKE FAILURE
PARKING BRAKE
FRONT HOOD
REAR HOOD (TRUNK)
HORN
LIGHTER
Fig. 3
PL INTRODUCTION 3
GENERAL INFORMATION (Continued)
6. FASTENER IDENTIFICATION
FASTENER IDENTIFICATION
THREAD IDENTIFICATION
SAE and metric bolt/nut threads are not the same.
The difference is described in the Thread Notation
chart (Fig. 4).
GRADE/CLASS IDENTIFICATION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 12.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts.
Fig. 4 Thread Notation—SAE and Metric
4 INTRODUCTION PL
GENERAL INFORMATION (Continued)
8. FASTENER STRENGTH
HOW TO DETERMINE BOLT STRENGTH Hexagon head bolt Bolt head No. Stud bolt No mark
No mark Hexagon
flange bolt
w/washer
hexagon bolt No mark Grooved
Hexagon head bolt
Two protruding
lines
Hexagon
flange bolt w/washer
hexagon bolt Two protruding lines
Welded bolt Hexagon head
bolt
Three protrud-
ing lines
Hexagon head
bolt Four protruding
lines
6 INTRODUCTION PL
GENERAL INFORMATION (Continued)
9. METRIC SYSTEM
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Figure art, specifications and torque references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage metric fasteners (nuts, bolts,
etc.) for reassembly. If the fastener is not salvage-
able, a fastener of equivalent specification should be
used.
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million (Fig.
5).
The following chart will assist in converting metric
units to equivalent English and SAE units, or vise
versa.
Refer to the Conversion Chart to convert torque
values listed in metric Newton- meters (N·m). Also,
use the chart to convert between millimeters (mm)
and inches (in.)
CONVERSION FORMULAS AND EQUIVALENT VALUES
Multiply By To Get Multiply By To Get
in-lbs x 0.11298 = Newton-Meters (N·m) N·m x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton-Meters (N·m) N·m x 0.7376 = ft-lbs
Inches Hg (60°F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters (M) M x 1.0936 = Yards
Miles x 1.6093 = Kilometers (Km) Km x 0.6214 = Miles
mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph
Feet/Sec. x 0.3048 = Meters/Sec. (M/S) M/S x 3.281 = Feet/Sec.
Kilometers/Hr. x 0.27778 = Meters/Sec. (M/S) M/S x 3.600 = Kilometers/Hr.
mph x 0.4470 = Meters/Sec. (M/S) M/S x 2.237 = mph
COMMON METRIC EQUIVALENTS
1 Inch = 25 Millimeters 1 Cubic
Inch
= 16 Cubic Centimeters
1 Foot = 0.3 Meter 1 Cubic
Foot
= 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic
Yard
= 0.8 Cubic Meter
1 Mile = 1.6 Kilometers
Mega - (M) Million Deci - (D) Tenth
Kilo - (K) Thousand Centi - (C) Hundredth
Milli - (m) Thousandth
Fig. 5 Metric Prefixes
PL INTRODUCTION 7
GENERAL INFORMATION (Continued)
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14. INTRODUCTION
CONTENTS
page page
GENERAL INFORMATION
E-MARK LABEL . . . . . . . . . . . . . . . . . . . . . . . . . 1
MANUFACTURER PLATE . . . . . . . . . . . . . . . . . . 2
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER
The Vehicle Identification Number (VIN) can be
viewed through the windshield at the upper left cor-
ner of the instrument panel next to the left A-pillar
on left-hand-drive vehicles (Fig. 1) and through the
windshield at the upper right corner of the instru-
ment panel next to the right A-pillar on right-hand-
drive vehicles (Fig. 2). The VIN consists of 17
characters in a combination of letters and numbers
that provide specific information about the vehicle.
Refer to the VIN Decoding Information Table to
interpret VIN code.
VIN CHECK DIGIT
To protect the consumer from theft and possible
fraud the manufacturer is required to include a check
Digit at the ninth position of the VIN. The check
digit is used by the manufacturer and government
agencies to verify the authenticity of the vehicle and
official documentation. The formula to use the check
digit is not released to the general public.
E-MARK LABEL
An E-mark Label (Fig. 3) is located on the rear
shut face of the driver’s door. The label contains the
following information:
• Date of Manufacture
• Month-Day-Hour (MDH)
• Vehicle Identification Number (VIN)
• Country Codes
• Regulation Number
• Regulation Amendment Number
• Approval Number
Fig. 1 VIN Plate Location — LHD
Fig. 2 VIN Plate Location — RHD
Fig. 3 E-Mark Label
PL INTRODUCTION 1
15. MANUFACTURER PLATE
The Manufacturer Plate (Fig. 4) is located in the
engine compartment on the right side of the radiator
closure panel crossmember adjacent. The plate con-
tains five lines of information:
1. Vehicle Identification Number (VIN)
2. Gross Vehicle Mass (GVM)
3. Gross Train Mass (GTM)
4. Gross Front Axle Rating (GFAR)
5. Gross Rear Axle Rating (GRAR)
VIN DECODING INFORMATION
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of origin 1 = United States
2 Make C = Chrysler
3 Vehicle Type 3 = Passenger Car
4 Passenger Safety E = Active Restraints, Driver and Passenger Airbags
5 Car Line S = Neon
6 Series M = DD5 5-Speed Manual Transmission
A = 3-Speed Automatic Transmission
7 Body Style 7 = 4 Door Pillared Hardtop
8 Engine C = 2.0L 4 Cyl. 16V SOHC
9 Check Digit See explanation in this section.
10 Model Year V = 1997
11 Assembly Plant D = Belvedere Assembly
12 Build Sequence 6 Digit number assigned by assembly plant
Fig. 4 Manufacturer Plate
2 INTRODUCTION PL
GENERAL INFORMATION (Continued)
16. LUBRICATION AND MAINTENANCE
CONTENTS
page page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
JUMP STARTING, TOWING AND HOISTING . . . 7
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
CLASSIFICATION OF LUBRICANTS . . . . . . . . . . 1
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . 2
INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
PARTS AND LUBRICANT
RECOMMENDATIONS . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
INTRODUCTION
Service and maintenance procedures for compo-
nents and systems listed in Schedule—A or B can be
found by using the Group Tab Locator index at the
front of this manual. If it is not clear which group
contains the information needed, refer to the index at
the back of this manual.
There are two maintenance schedules that show
proper service based on the conditions that the vehi-
cle is subjected to.
Schedule— A , lists scheduled maintenance to be
performed when the vehicle is used for general trans-
portation.
Schedule— B , lists maintenance intervals for vehi-
cles that are operated under the conditions listed at
the beginning of the Maintenance Schedule section.
Use the schedule that best describes your driving
conditions.
Where time and mileage are listed, follow the
interval that occurs first.
PARTS AND LUBRICANT RECOMMENDATIONS
When service is required, Chrysler Corporation
recommends that only Mopart brand parts, lubri-
cants and chemicals be used. Mopar provides the
best engineered products for servicing Chrysler Cor-
poration vehicles.
INTERNATIONAL SYMBOLS
Chrysler Corporation uses international symbols to
identify engine compartment lubricant and fluid
inspection and fill locations (Fig. 1).
Fig. 1 International Symbols
ENGINE OIL
AUTOMATIC
TRANSMISSION
FLUID
ENGINE COOLANT BRAKE FLUID
POWER STEERING
FLUID
WINDSHIELD
WASHER FLUID
PL LUBRICATION AND MAINTENANCE 0 - 1