Dodge Neon 1995–1999 Factory Service Manual

This Chrysler factory service manual covers 1998 Dodge and Plymouth Neon/Neon Expresso two- and four-door models. The integrated 1999 Chrysler Neon export sections cover four-door left- and right-hand-drive cars with 1.8L or 2.0L SOHC engines and either the DD5 five-speed manual or a three-speed automatic. Use the 1999 sections for the Chrysler export configurations.

PDF Bookmarks and Wiring Detail

Finding procedures and circuit labels — The service text and many wiring labels are searchable. Some illustrations and diagnostic charts have labels embedded as images. The PDF bookmarks lead to chapters and individual topics. Use them in place of the links on the opening chapter locator, which point to separate files. Zoom in to read small wire codes and pin numbers on dense diagrams.

The ZIP contains one 1,217-page printable PDF, including the chapter locator, integrated export sections, and 37 blank pages. The archive also contains a separate Adobe Reader installer.

Engine, Chassis, and Electrical Service

The sections below are selected highlights. The manual also covers starter and charging-system tests and headlamp aiming.

• SOHC and DOHC engines — Compression, cylinder leakage, and oil-pressure tests, plus engine removal, cylinder-head and valvetrain repair, and timing-belt service.
• Steering and suspension — Front MacPherson and rear strut service, wheel alignment, adjustable S/C ACR Competition Package struts, hub bearings, and steering-gear repair.
• Brakes and Teves Mark 20 ABS — Disc and drum service, parking brake adjustment, hydraulic bleeding, proportioning-valve tests, wheel-speed sensor checks, and DRB scan-tool diagnostics.
• Manual and automatic transaxles — NV T350 (A-578) and 31TH removal and overhaul, with synchronizer work for the manual and hydraulic pressure tests for the automatic.
• Wiring diagrams — Left-hand-drive, right-hand-drive, and built-up export layouts with connector pinouts, ground points, splice locations, and harness routing.
• Cooling and HVAC — Cooling-system pressure and flow tests, radiator fan diagnosis, A/C performance checks, refrigerant leak detection, and compressor clutch service.

The manual suits technicians familiar with workshop testing and overhaul procedures. Jobs such as transaxle bearing preload and ABS fault isolation call for dedicated measuring equipment or a DRB scan tool.

Timing Belts, Fuel Delivery, and Maintenance

The engine chapters distinguish mechanical and hydraulic timing-belt tensioners and cover crankshaft, piston, connecting-rod, oil-pump, and seal service. The 1.8L export section supplies its own engine specifications and directs shared work to the 2.0L SOHC procedures. The manual warns that rotating either 2.0L engine with the timing belt off can damage the valvetrain.

Maintenance schedules sit alongside water-pump and thermostat service, fuel delivery and injection diagnosis, and EVAP and EGR checks. The 1.8L fuel and emissions sections identify the procedures shared with the 2.0L engine.

Clutch Variants and Transaxle Overhaul

The NV T350 gear-ratio chart distinguishes cable-operated and right-hand-drive hydraulic clutch applications and identifies variants with a reverse brake. The identification notes help match a replacement unit by assembly number when the housings look alike. The manual also covers differential bearing preload, shift-rail overhaul, and the output shaft as a service unit.

The 31TH chapter pairs its hydraulic schematic with road tests and clutch and servo air checks to help isolate shift complaints. It covers valve-body and pump work, planetary and transfer-shaft service, shim selection, band adjustment, and final checks. Cooler flushing calls out tool 6906A.

Hub Bearings, ABS, and Wiring

Chassis procedures include driveshaft reconditioning, tripod and outer CV joints, steering pump pressure and flow tests, and steering-column service. Front strut and ball-joint work calls out tools L-4558A and 6758. The manual warns that rolling or loading the car after the front hub nut is loosened can damage the bearing.

The brake chapters cover rotor and drum machining, intermittent ABS codes, tonewheels, and the hydraulic control unit. The manual flags the Teves Mark 20 tonewheels as specific to the later configuration and warns against fitting them to pre-1998 models.

Wiring groups 8W-10, 8W-35, and 8W-43 cover power distribution, ABS, and airbags. Groups 8W-80 and 8W-90 pair connector pinouts with location views for circuit tracing. Immobilizer, remote keyless entry, and power accessory circuits are also included. Selected powertrain, airbag, immobilizer, and ABS fault trees require the separate Chrysler diagnostic manuals referenced in the text.

Climate Control and Body Service

The HVAC chapter covers evacuation and charging, condenser and evaporator replacement, and heater-core and air-distribution-module service. Body procedures cover doors, glass, seats, the instrument panel, trim, and sunroof adjustments.

Brake, airbag, refrigerant, and major powertrain repair requires the correct lifting, isolation, recovery, and test equipment. Those jobs should be handled by technicians with the training and tools specified for the system.

Sample Compression, Torque, and Coolant Specs

The 1.8L SOHC specifications list cranking compression of 170–225 psi, with a maximum variation of 25% between cylinders.

The front suspension torque table lists 183 N·m (135 lb-ft) for the front stub axle-to-hub bearing nut.

The maintenance chapter lists a cooling-system capacity of 6 L, including the heater and coolant recovery bottle.