Dodge Neon, Plymouth Neon Repair Manual 1995-1999

This repair and service manual covers Dodge Neon and Plymouth Neon 1995, 1996, 1997, 1998, 1999, U.S. and Canadian models.
Book Excerpt: 1995-1999 Dodge, Plymouth Neon Repair Manual ENGINE AND ENGINE OVERHAUL

CYLINDER HEAD | REMOVAL AND INSTALLATION
(See Figures 82 thru 99)

1. Disconnect the negative battery cable.
2. Properly remove the fuel system pressure, as outlined in Section 5 of this manual.
3. Drain the cooling system into a suitable container.
4. Remove the air cleaner inlet duct and air cleaner. Tag and disconnect all vacuum lines , electrical wiring and fuel lines from the throttle body.
5. Remove the throttle linkage.
6. Remove the accessory drive belts, as outlined in Section 1.
7. Disconnect the power brake vacuum hose from the intake manifold.
8. Raise and safely support the vehicle, then separate the exhaust pipe from the manifold. Carefully lower the vehicle.
9. Unbolt the power steering pump and set aside. Do NOT disconnect the fluid lines!
10. Detach the ignition coil pack wiring connector, then remove the coil pack and bracket from the engine.
11. Detach the cam sensor and fuel injector electrical connectors.
12. For 1996-99 vehicles, remove the intake manifold.
13. For SOHC engines, remove the timing belt and camshaft sprocket.
14. For DOHC engines, remove the timing belt, timing belt tensioner and camshaft sprocket. Remove the inner timing belt cover.
15. Remove the rocker arm (valve) cover.
16. For SOHC engine, remove the rocker arm shaft assemblies.
17. For DOHC engines, remove the camshaft and cam follower assemblies.
18. For SOHC engines, if necessary, remove the oil separator assembly bolts, then remove the oil separator.
19. For SOHC engines, unfasten the hose clamps, then disconnect the heater hoses. Remove any remaining hoses or lines.
20. Use a ratchet to unfasten the cylinder head bolts, working from the center outward, then remove the cylinder head from the engine block.
21. The cylinder head bolts must be inspected before they can be reused. If the thread bolts are stretched, they must be replaced. Check the thread stretching by holding a scale or other straight edge against the threads. If all the threads do not contact the scale, the bolts must be replaced.

SUSPENSION AND STEERING

WHEELS | WHEEL ASSEMBLY REMOVAL AND INSTALLATION (See figures 1, 2 and 3) NOTE: Vehicles equipped with 13 inch tires have a 4 stud wheel mounting system. Vehicles equipped with 14 inch tires have either a 4 or 5 stud wheel mounting system.

1. Park the vehicle on a level surface.
2. Remove the jack, tire iron and if necessary, the spare tire from their storage compartments.
3. Check the owners manual or refer to Section 1 of this manual for the jacking points on your vehicle. Then, place the jack in the proper position.
4. If equipped with lug nut trim caps, remove them by either unscrewing or pulling them off the lug nuts, as appropriate. Consult the owners manual, if necessary.
5. if equipped with a wheel cover or hub cap, insert the tapered end of the tire iron in the groove and pry off the cover.
6. Apply the parking brake and block the diagonally opposite wheel with a wheel chock or two.
TIP! Wheel chocks may be purchased at your local auto parts store, or a block of wood cut into wedges may be used. If possible, keep one or two chocks in your tire storage compartment, in case any of the tires has to be removed on the side of the road.
7. If equipped with an automatic transaxle, place the selector lever in P or Park; with a manual transaxle, place the shifter in Reverse.
8. With the tires still on the ground, use the tire iron/wrench to break the lug nuts loose.
TIP! If a nut is stuck, never use heat to loosen it or damage to the wheel and bearings may occur. If the nuts are seized, one or two heavy hammer blows directly on the end of the bolt usually loosens the rust. Be careful, as continued pounding will likely damage the brake drum or rotor.
9. Using the jack, raise the vehicle until the tire is clear of the ground. Support the vehicle safely using jack stands.
10. Remove the lug nuts, then remove the tire and wheel assembly.

Subject: 1995, 1996, 1997, 1998, 1999 Dodge, Plymouth Neon service, maintenance, repair. ISBN-10: 080198971X | ISBN-13: 9780801989711 | Chilton 20600