DODGE NEON SX 2 SRT 4 Service Repair Manual 2004-2007

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🏷️ Basic Information Identification Make: Dodge Model: Neon Trim Level: SX, SRT-4 Year: 2004-2007 Codes Platform: PG (Chrysler's second-generation Neon platform) Engine Code Neon: EDZ (2.0L SOHC I4), EAS (2.4L DOHC Turbo I4 - SRT-4) Vin Engine Designator: G (2.0L), Z (2.4L Turbo) 👋 Introduction Market Position Segment: Compact Car, Sport Compact (SRT-4) Target Audience: DIY enthusiasts, independent repair shops, Dodge Neon owners seeking detailed repair information. Competitive Analysis Competitors: Honda Civic Si, Acura RSX, Mazda3s, Subaru Impreza WRX (SRT-4 specifically) Key Features Value Proposition: Comprehensive coverage for a performance-oriented compact, offering deep insights into both standard and high-performance variants. Manual Advantage: Provides factory-level detail often missing in aftermarket manuals, crucial for complex systems like the SRT-4's turbocharged engine and performance drivetrain. 📋 Manual Details Coverage Areas Manual Type: Factory Service Manual / Repair Manual Language: English Format: PDF Original Source: Dodge/Chrysler Factory Documentation Page Count Estimated Page Count: Hundreds of Pages (Specific count not provided, but typical for full service manuals) 📖 Manual Coverage Systems Covered Engine: 2.0L SOHC I4 (EDZ), 2.4L DOHC Turbo I4 (EAS/BPT) Transmission: 5-Speed Manual (Getrag/Chrysler New Venture Gear), 4-Speed Automatic (41TE) Drivetrain: Front Wheel Drive (FWD) Suspension: Front: MacPherson Strut, Rear: Multi-link Independent Brakes: Front: Disc (Vented), Rear: Disc. ABS, Rear Brake proportioning valve Steering: Power Rack and Pinion Electrical: Battery, Charging System, Starting System, Ignition System, Lighting, Gauges, Wipers, Power Accessories, Body Control Module (BCM), Powertrain Control Module (PCM) HVAC: Heating, Ventilation, Air Conditioning System (Refrigerant, Compressor, Evaporator, Condenser, Blower Motor) Fuel System: Fuel Delivery, Fuel Pump, Injectors, Fuel Tank, Evaporative Emission Control (EVAP) Exhaust System: Catalytic Converter, Muffler, Exhaust Manifold, Oxygen Sensors Body And Frame: Body Panels, Doors, Hood, Trunk, Bumpers, Chassis, Frame Interior: Seats, Dashboard, Trim Panels, Restraints (Airbags, Seatbelts) Procedures Included Maintenance: Oil Change, Filter Replacement, Spark Plug Replacement, Coolant Flush, Belt Inspection/Replacement, Brake Fluid Flush, Air Filter Replacement, Cabin Air Filter Replacement Troubleshooting: Diagnostic Fault Codes (DTCs), Symptom-based Diagnosis, Component Testing Repair: Engine Overhaul, Transmission Rebuild, Brake System Repair, Suspension Component Replacement, Electrical System Repair, HVAC Component Replacement, Body Panel Repair Rebuild: Engine Assembly, Transmission Disassembly and Reassembly, Turbocharger Rebuild (SRT-4) Restoration: Bodywork, Paint, Interior Refurbishment, Mechanical Component Restoration Installation: Component Replacement (e.g., alternator, starter, water pump), Aftermarket Part Installation Guidelines (if applicable) Diagnostics: Wiring Diagrams, Exploded Views, Torque Specifications, Measurement Data, Scan Tool Procedures Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including electrical schematics and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely Text-Searchable (if professionally converted from original) Print Quality Quality: Dependent on source; generally high for factory manuals, ensuring clear diagrams and text. Binding Type Binding: N/A (Digital PDF Format) Paper Type Paper: N/A (Digital PDF Format) ⚙️ Engine Specifications Primary Engine Engine 1 Type: DOHC Inline-4 Engine 1 Displacement: 1996 cc (2.0 L) Engine 1 Bore X Stroke: 87.5 mm x 83.0 mm Engine 1 Compression Ratio: 9.7:1 Engine 1 Horsepower: 132 hp @ 6000 rpm (Approx.) Engine 1 Torque: 130 lb-ft @ 4500 rpm (Approx.) Engine 2 Type: DOHC Turbocharged Inline-4 (SRT-4) Engine 2 Displacement: 2429 cc (2.4 L) Engine 2 Bore X Stroke: 87.5 mm x 101.0 mm Engine 2 Compression Ratio: 8.1:1 Engine 2 Horsepower: 215-230 hp @ 5300-5500 rpm (varies by year/tune) Engine 2 Torque: 240-245 lb-ft @ 2200-2400 rpm (varies by year/tune) Performance Turbocharger System Srt4: Garrett GT15 Turbocharger, Intercooler, Wastegate Control Engine Control Module ECM: Chrysler Powertrain Control Module (PCM) - Programmable for performance tuning Fuel System Fuel Type: Unleaded Gasoline Fuel Injection: Multi-port Fuel Injection (MPFI) / Sequential Electronic Fuel Injection (SEFI) Fuel Pump Pressure: 3.0-3.5 bar (44-51 psi) (Typical) Ignition System: Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or Coil Packs 🔧 Transmission Standard Transmission Type: 5-Speed Manual Transmission Transmission Manufacturer: Getrag / Chrysler New Venture Gear (NVG) Gear Ratios Manual: Specific ratios vary by model year; manual includes close-ratio gearing for SRT-4 Optional Transmission Type Optional: 4-Speed Automatic Transmission (41TE) Features Clutch Type Manual: Hydraulically Actuated Single Dry Plate Clutch Transmission Fluid Type Manual: API GL-4, SAE 75W-90 Synthetic Gear Lubricant (Consult specific manual for exact spec) Transmission Fluid Type Automatic: ATF+4 (Chrysler Material Standard MS-9602) Differential: Integrated into transmission housing, often with limited-slip differential (LSD) option for SRT-4 📐 Dimensions Exterior Length: Approx. 174.4 inches (4430 mm) Width: Approx. 67.7 inches (1720 mm) Height: Approx. 55.4 inches (1407 mm) Wheelbase: Approx. 104.4 inches (2652 mm) Front Track: Approx. 58.0 inches (1473 mm) Rear Track: Approx. 58.0 inches (1473 mm) Wheel Bolt Pattern: 5 x 100 mm Wheel Size: 16-inch (SX), 17-inch (SRT-4) Tire Size Sx: 205/50R16 (Typical) Tire Size Srt4: 225/45R17 (Typical) Weights Curb Weight: Approx. 2800-3200 lbs (1270-1450 kg) (Varies by trim and equipment) Gross Vehicle Weight Rating Gvwr: Consult vehicle placard 🛡️ Safety Features Ratings NHTSA Front Crash Rating: Good (for the generation,...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Trim Level:

SX, SRT-4

Year:

2004-2007

Codes

Platform:

PG (Chrysler's second-generation Neon platform)

Engine Code Neon:

EDZ (2.0L SOHC I4), EAS (2.4L DOHC Turbo I4 - SRT-4)

Vin Engine Designator:

G (2.0L), Z (2.4L Turbo)

👋 Introduction

Market Position

Segment:

Compact Car, Sport Compact (SRT-4)

Target Audience:

DIY enthusiasts, independent repair shops, Dodge Neon owners seeking detailed repair information.

Competitive Analysis

Competitors:

Honda Civic Si, Acura RSX, Mazda3s, Subaru Impreza WRX (SRT-4 specifically)

Key Features

Value Proposition:

Comprehensive coverage for a performance-oriented compact, offering deep insights into both standard and high-performance variants.

Manual Advantage:

Provides factory-level detail often missing in aftermarket manuals, crucial for complex systems like the SRT-4's turbocharged engine and performance drivetrain.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Original Source:

Dodge/Chrysler Factory Documentation

Page Count

Estimated Page Count:

Hundreds of Pages (Specific count not provided, but typical for full service manuals)

📖 Manual Coverage

Systems Covered

Engine:

2.0L SOHC I4 (EDZ), 2.4L DOHC Turbo I4 (EAS/BPT)

Transmission:

5-Speed Manual (Getrag/Chrysler New Venture Gear), 4-Speed Automatic (41TE)

Drivetrain:

Front Wheel Drive (FWD)

Suspension:

Front: MacPherson Strut, Rear: Multi-link Independent

Brakes:

Front: Disc (Vented), Rear: Disc. ABS, Rear Brake proportioning valve

Steering:

Power Rack and Pinion

Electrical:

Battery, Charging System, Starting System, Ignition System, Lighting, Gauges, Wipers, Power Accessories, Body Control Module (BCM), Powertrain Control Module (PCM)

HVAC:

Heating, Ventilation, Air Conditioning System (Refrigerant, Compressor, Evaporator, Condenser, Blower Motor)

Fuel System:

Fuel Delivery, Fuel Pump, Injectors, Fuel Tank, Evaporative Emission Control (EVAP)

Exhaust System:

Catalytic Converter, Muffler, Exhaust Manifold, Oxygen Sensors

Body And Frame:

Body Panels, Doors, Hood, Trunk, Bumpers, Chassis, Frame

Interior:

Seats, Dashboard, Trim Panels, Restraints (Airbags, Seatbelts)

Procedures Included

Maintenance:

Oil Change, Filter Replacement, Spark Plug Replacement, Coolant Flush, Belt Inspection/Replacement, Brake Fluid Flush, Air Filter Replacement, Cabin Air Filter Replacement

Troubleshooting:

Diagnostic Fault Codes (DTCs), Symptom-based Diagnosis, Component Testing

Repair:

Engine Overhaul, Transmission Rebuild, Brake System Repair, Suspension Component Replacement, Electrical System Repair, HVAC Component Replacement, Body Panel Repair

Rebuild:

Engine Assembly, Transmission Disassembly and Reassembly, Turbocharger Rebuild (SRT-4)

Restoration:

Bodywork, Paint, Interior Refurbishment, Mechanical Component Restoration

Installation:

Component Replacement (e.g., alternator, starter, water pump), Aftermarket Part Installation Guidelines (if applicable)

Diagnostics:

Wiring Diagrams, Exploded Views, Torque Specifications, Measurement Data, Scan Tool Procedures

Technical Depth

Depth:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including electrical schematics and diagnostic procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely Text-Searchable (if professionally converted from original)

Print Quality

Quality:

Dependent on source; generally high for factory manuals, ensuring clear diagrams and text.

Binding Type

Binding:

N/A (Digital PDF Format)

Paper Type

Paper:

N/A (Digital PDF Format)

⚙️ Engine Specifications

Primary Engine

Engine 1 Type:

DOHC Inline-4

Engine 1 Displacement:

1996 cc (2.0 L)

Engine 1 Bore X Stroke:

87.5 mm x 83.0 mm

Engine 1 Compression Ratio:

9.7:1

Engine 1 Horsepower:

132 hp @ 6000 rpm (Approx.)

Engine 1 Torque:

130 lb-ft @ 4500 rpm (Approx.)

Engine 2 Type:

DOHC Turbocharged Inline-4 (SRT-4)

Engine 2 Displacement:

2429 cc (2.4 L)

Engine 2 Bore X Stroke:

87.5 mm x 101.0 mm

Engine 2 Compression Ratio:

8.1:1

Engine 2 Horsepower:

215-230 hp @ 5300-5500 rpm (varies by year/tune)

Engine 2 Torque:

240-245 lb-ft @ 2200-2400 rpm (varies by year/tune)

Performance

Turbocharger System Srt4:

Garrett GT15 Turbocharger, Intercooler, Wastegate Control

Engine Control Module ECM:

Chrysler Powertrain Control Module (PCM) - Programmable for performance tuning

Fuel System

Fuel Type:

Unleaded Gasoline

Fuel Injection:

Multi-port Fuel Injection (MPFI) / Sequential Electronic Fuel Injection (SEFI)

Fuel Pump Pressure:

3.0-3.5 bar (44-51 psi) (Typical)

Ignition System:

Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or Coil Packs

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual Transmission

Transmission Manufacturer:

Getrag / Chrysler New Venture Gear (NVG)

Gear Ratios Manual:

Specific ratios vary by model year; manual includes close-ratio gearing for SRT-4

Optional

Transmission Type Optional:

4-Speed Automatic Transmission (41TE)

Features

Clutch Type Manual:

Hydraulically Actuated Single Dry Plate Clutch

Transmission Fluid Type Manual:

API GL-4, SAE 75W-90 Synthetic Gear Lubricant (Consult specific manual for exact spec)

Transmission Fluid Type Automatic:

ATF+4 (Chrysler Material Standard MS-9602)

Differential:

Integrated into transmission housing, often with limited-slip differential (LSD) option for SRT-4

📐 Dimensions

Exterior

Length:

Approx. 174.4 inches (4430 mm)

Width:

Approx. 67.7 inches (1720 mm)

Height:

Approx. 55.4 inches (1407 mm)

Wheelbase:

Approx. 104.4 inches (2652 mm)

Front Track:

Approx. 58.0 inches (1473 mm)

Rear Track:

Approx. 58.0 inches (1473 mm)

Wheel Bolt Pattern:

5 x 100 mm

Wheel Size:

16-inch (SX), 17-inch (SRT-4)

Tire Size Sx:

205/50R16 (Typical)

Tire Size Srt4:

225/45R17 (Typical)

Weights

Curb Weight:

Approx. 2800-3200 lbs (1270-1450 kg) (Varies by trim and equipment)

Gross Vehicle Weight Rating Gvwr:

Consult vehicle placard

🛡️ Safety Features

Ratings

NHTSA Front Crash Rating:

Good (for the generation, though specific year ratings may vary)

IIHS Front Offset Crash Rating:

Acceptable to Good (for the generation)

Active Features

Standard on most trims, optional on some base models.

Traction Control:

Optional or standard on some higher trims/later years.

Electronic Stability Control Esc:

Not commonly available for this generation.

Passive Features

Airbags:

Frontal airbags standard. Side curtain airbags optional/standard on some trims.

Seatbelts:

3-point front and rear seatbelts with pretensioners for front seats.

Child Seat Anchors:

LATCH system (Lower Anchors and Tethers for Children) standard.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player. Optional Infinity speaker system and subwoofer. Sirius Satellite Radio capability on some models.

Navigation:

No factory integrated navigation system available for this generation.

Driver Assistance

Cruise Control:

Standard on most trims.

Anti Theft System:

Factory immobilizer system.

Connectivity

Auxiliary Input:

Not typically equipped with standard aux input; aftermarket solutions or specific head unit upgrades may be required.

Bluetooth:

Not available from the factory.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-7,500 miles or 6-12 months (depending on oil type and driving conditions).

Air Filter Replacement Interval:

Every 15,000-30,000 miles or as needed based on inspection.

Spark Plug Replacement Interval:

Every 60,000-100,000 miles (depending on plug type, iridium recommended for longevity).

Coolant Flush Interval:

Every 50,000-100,000 miles or 5 years (using HOAT coolant).

Transmission Fluid Change Interval Auto:

Every 30,000-60,000 miles (check manual for specific recommendation).

Transmission Fluid Change Interval Manual:

Inspect at 30,000 miles, replace if necessary or at higher mileage intervals (e.g., 80,000-100,000 miles).

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (API SN or SP certified). For SRT-4, synthetic is highly recommended. Consult manual for specific viscosity recommendations based on temperature.

Engine Oil Capacity:

Approx. 4.5 quarts (4.2 Liters) with filter for 2.0L, Approx. 4.5 quarts (4.2 Liters) with filter for 2.4L Turbo.

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 (Check manual for specific recommendation and DOT rating compatibility).

Known Issues

Engine Mounts:

Can degrade over time, leading to vibration and engine movement, particularly noticeable on SRT-4.

Turbo Charger Srt4:

Potential for wastegate actuator failure, oil seal leaks, or turbine damage if not properly maintained or if oil is neglected.

Clutch Wear Srt4:

High-performance clutch can wear out faster under aggressive driving conditions.

Suspension Components:

Worn ball joints, tie rod ends, and bushings can lead to steering looseness and tire wear.

Exhaust Manifold Cracks Srt4:

The factory exhaust manifold is prone to cracking due to heat cycling. Upgraded aftermarket manifolds are common.

Intercooler Pipes Srt4:

Stock intercooler piping can develop leaks or cracks, impacting boost pressure.

Power Steering Pump:

Can develop leaks or noise over time.

📚 Vehicle History

Brand Heritage

Brand History Context:

Dodge, a division of Chrysler (now Stellantis), has a long history of producing performance-oriented vehicles. The Neon nameplate was introduced to compete in the compact segment.

Model Evolution

Neon Generations:

First Generation (1994-1999), Second Generation (2000-2005), Third Generation (2005-2011, rebadged Mitsubishi Lancer for Mexico/some markets; North American market focus on SRT-4 version of 2nd gen). This manual covers the latter part of the second generation and its performance variants.

Srt4 Introduction:

The SRT-4 variant was introduced for the 2003 model year, significantly boosting the Neon's performance image with a turbocharged engine and upgraded chassis components.

Platform Changes:

The PG platform (2nd Gen Neon) received styling updates and improved chassis dynamics over its predecessor.

Production

Manufacturing Location:

Belvidere, Illinois, USA

Production Years Covered:

2004, 2005, 2006, 2007

🏆 Awards & Recognition

Recognitions

Car And Driver 2004:

Car and Driver's 10Best list for the SRT-4 variant in 2004.

Sport Compact Recognition:

SRT-4 frequently recognized as a top-performing sport compact of its era.