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Dodge Neon SRT4 2003-2005 Service Repair Workshop Manual Pdf

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🏷️ Basic Information Identification Make: Dodge Model: Neon SRT-4 Model Generation: Second Generation (PT Body) Production Years Covered: 2003, 2004, 2005 Platform: Chrysler PT platform (modified) Codes Chassis Code: PT 👋 Introduction Market Position Market Niche: High-performance compact sedan from Dodge, targeting enthusiasts seeking affordable power Competitive Analysis Key Competitors: Subaru WRX, Mitsubishi Lancer Evolution, Honda Civic Si, Volkswagen GTI Key Features Performance Focus: Emphasis on turbocharged engine power, sport-tuned suspension, and aggressive styling Value Proposition: Offers significant performance for its price point, making it an attractive option for tuners and performance enthusiasts Manual Value Purpose For Buyers: Essential resource for maintenance, repair, and performance modification of the Neon SRT-4 📋 Manual Details Coverage Areas Coverage Focus: Comprehensive factory service and repair Target Audience: Professional technicians and DIY enthusiasts Page Count Estimated Page Count: 1500-2000+ Manual Type Manual Type: Service Repair Workshop Manual Language Language: English Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, diagnosis, repair of all engine components (block, head, pistons, crank, camshafts, timing) Engine Performance: Turbocharger system, intercooler, intake manifold, exhaust system, fuel injection, ignition system, emissions control Transmission: Getrag® Heavy Duty Manual Transmission (NVT5500), clutch system, linkage, diagnosis, repair Drivetrain: Front-wheel drive system, CV joints, drive axles, differential Suspension: Front MacPherson struts, rear independent suspension, springs, shock absorbers, control arms, anti-roll bars, alignment specifications Steering: Power steering system, rack and pinion, pump, hoses, diagnosis Brakes: Front and rear disc brakes, ABS system, hydraulic lines, calipers, rotors, pads, parking brake Electrical System: 12V battery, alternator, starter motor, lighting, fuses, relays, wiring diagrams, Body Control Module (BCM) HVAC: Air conditioning system, heater core, blower motor, controls, refrigerant handling Body And Interior: Exterior panels, doors, windows, seats, dashboard, trim, structural components, glass replacement Body Electrical: Power windows, power locks, remote keyless entry, interior lighting, gauges, warning lights Diagnostic Troubleshooting: OBD-II diagnostic procedures, trouble code interpretation, symptom-based troubleshooting guides Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, coolant flushes, brake fluid changes Component Replacement: Detailed step-by-step instructions for replacing virtually all major and minor components Engine Rebuild: Complete procedures for engine disassembly, inspection, machining, and reassembly Turbocharger Service: Diagnosis, repair, and replacement of the turbocharger and associated plumbing Suspension Geometry: Alignment procedures, caster, camber, toe angle adjustments Brake System Overhaul: Bleeding procedures, caliper rebuild, rotor replacement Electrical Diagnostics: Tracing electrical faults, testing circuits, component testing HVAC Service: Refrigerant charging, leak detection, component replacement Body Panel Repair: Dent removal, panel alignment, replacement procedures Troubleshooting Guides: System-specific diagnostic flowcharts and problem resolution steps Technical Depth Depth Of Coverage: Factory-level detail, suitable for comprehensive repair and diagnosis Diagnostic Tools: Specifies use of diagnostic scan tools, multimeters, and specialized testing equipment Torque Specifications: Includes precise torque values for all fasteners Clearances And Tolerances: Provides critical engine and chassis component clearances and wear tolerances 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Print Quality Print Quality: High-resolution, printable pages Binding Type Binding Type: N/A (Digital download) Paper Type Paper Type: N/A (Digital download) Searchability Searchability: Text-searchable PDF for quick information retrieval Navigation Navigation: Includes bookmarks and table of contents for easy navigation ⚙️ Engine Specifications Primary Engine Engine Code: GEMA (2.4L DOHC Turbocharged Inline-4) Displacement: 2378 cc (2.4 Liters) Bore X Stroke: 87.5 mm x 98.0 mm Compression Ratio: 8.1:1 Valvetrain: Dual Overhead Camshafts (DOHC), 16 valves, timing belt Aspiration: Turbocharged with intercooler Turbocharger Model: Garrett® T3/T4E (often customized/upgraded) Performance Horsepower: 230 hp @ 5300 rpm (Stock) Torque: 250 lb-ft @ 3200 rpm (Stock) Redline: 6500 rpm Fuel System Fuel Delivery: Electronic Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded gasoline, premium recommended (91 octane or higher) Fuel Injectors: High-flow injectors required for moderate tuning Engine Management ECU Type: Factory ECU, often remapped or replaced for tuning 🔧 Transmission Standard Transmission Type: Getrag® Heavy Duty Manual (NVT5500) Number Of Gears: 5-speed manual Optional Optional Transmission: N/A (Exclusively manual transmission) Features Gear Ratios: Specific gear ratios available in the manual Clutch Type: Single dry plate, hydraulic actuation Fluid Specifications Transmission Fluid Type: Manual Transmission Fluid (MTF), e.g., Mopar® Manual Transmission Lubricant or equivalent Fluid Capacity Transmission Fluid Capacity: Approximately 2.3 Liters (check manual for exact specification) 📐 Dimensions Exterior Length: 174.4 inches (4430 mm) Width: 67.7 inches (1720 mm) Height: 55.8 inches (1417 mm) Wheelbase: 105.1 inches (2670 mm) Front Track: 58.2 inches (1478 mm) Rear Track: 58.0 inches (1473 mm) Weights Curb Weight: 2995 lbs (1360 kg) Gross Vehicle Weight Rating: Approx. 3800 lbs (1724 kg) Cargo Trunk Volume: 13.0 cubic feet (368 Liters) Wheels And Tires Standard Wheel Size: 17 x 7.5 inches Standard Tire Size: 205/50R17 Wheel Bolt Pattern: 5 x 100 mm Wheel Offset: ET40 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: 4-star (2003) NHTSA Frontal Impact Passenger: 4-star (2003) IIHS Front Offset Test: Good (2003-2005) Active Features ABS: Standard Anti-lock...
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Dodge Neon SRT4 2003-2005 Service Repair Workshop Manual Pdf
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Neon SRT-4
Model Generation:
Second Generation (PT Body)
Production Years Covered:
2003, 2004, 2005
Platform:
Chrysler PT platform (modified)
Codes
Chassis Code:
PT
👋 Introduction
Market Position
Market Niche:
High-performance compact sedan from Dodge, targeting enthusiasts seeking affordable power
Competitive Analysis
Key Competitors:
Subaru WRX, Mitsubishi Lancer Evolution, Honda Civic Si, Volkswagen GTI
Key Features
Performance Focus:
Emphasis on turbocharged engine power, sport-tuned suspension, and aggressive styling
Value Proposition:
Offers significant performance for its price point, making it an attractive option for tuners and performance enthusiasts
Manual Value
Purpose For Buyers:
Essential resource for maintenance, repair, and performance modification of the Neon SRT-4
📋 Manual Details
Coverage Areas
Coverage Focus:
Comprehensive factory service and repair
Target Audience:
Professional technicians and DIY enthusiasts
Page Count
Estimated Page Count:
1500-2000+
Manual Type
Manual Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF (Downloadable)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, diagnosis, repair of all engine components (block, head, pistons, crank, camshafts, timing)
Engine Performance:
Turbocharger system, intercooler, intake manifold, exhaust system, fuel injection, ignition system, emissions control
Transmission:
Getrag® Heavy Duty Manual Transmission (NVT5500), clutch system, linkage, diagnosis, repair
Drivetrain:
Front-wheel drive system, CV joints, drive axles, differential
Suspension:
Front MacPherson struts, rear independent suspension, springs, shock absorbers, control arms, anti-roll bars, alignment specifications
Steering:
Power steering system, rack and pinion, pump, hoses, diagnosis
Brakes:
Front and rear disc brakes, ABS system, hydraulic lines, calipers, rotors, pads, parking brake
Electrical System:
12V battery, alternator, starter motor, lighting, fuses, relays, wiring diagrams, Body Control Module (BCM)
HVAC:
Air conditioning system, heater core, blower motor, controls, refrigerant handling
Body And Interior:
Exterior panels, doors, windows, seats, dashboard, trim, structural components, glass replacement
Body Electrical:
Power windows, power locks, remote keyless entry, interior lighting, gauges, warning lights
Diagnostic Troubleshooting:
OBD-II diagnostic procedures, trouble code interpretation, symptom-based troubleshooting guides
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug service, coolant flushes, brake fluid changes
Component Replacement:
Detailed step-by-step instructions for replacing virtually all major and minor components
Engine Rebuild:
Complete procedures for engine disassembly, inspection, machining, and reassembly
Turbocharger Service:
Diagnosis, repair, and replacement of the turbocharger and associated plumbing
Suspension Geometry:
Alignment procedures, caster, camber, toe angle adjustments
Brake System Overhaul:
Bleeding procedures, caliper rebuild, rotor replacement
Electrical Diagnostics:
Tracing electrical faults, testing circuits, component testing
HVAC Service:
Refrigerant charging, leak detection, component replacement
Body Panel Repair:
Dent removal, panel alignment, replacement procedures
Troubleshooting Guides:
System-specific diagnostic flowcharts and problem resolution steps
Technical Depth
Depth Of Coverage:
Factory-level detail, suitable for comprehensive repair and diagnosis
Diagnostic Tools:
Specifies use of diagnostic scan tools, multimeters, and specialized testing equipment
Torque Specifications:
Includes precise torque values for all fasteners
Clearances And Tolerances:
Provides critical engine and chassis component clearances and wear tolerances
📊 Manual Specifications
File Format
File Format:
Portable Document Format (PDF)
Print Quality
Print Quality:
High-resolution, printable pages
Binding Type
Binding Type:
N/A (Digital download)
Paper Type
Paper Type:
N/A (Digital download)
Searchability
Searchability:
Text-searchable PDF for quick information retrieval
Navigation
Navigation:
Includes bookmarks and table of contents for easy navigation
⚙️ Engine Specifications
Primary Engine
Engine Code:
GEMA (2.4L DOHC Turbocharged Inline-4)
Displacement:
2378 cc (2.4 Liters)
Bore X Stroke:
87.5 mm x 98.0 mm
Compression Ratio:
8.1:1
Valvetrain:
Dual Overhead Camshafts (DOHC), 16 valves, timing belt
Aspiration:
Turbocharged with intercooler
Turbocharger Model:
Garrett® T3/T4E (often customized/upgraded)
Performance
Horsepower:
230 hp @ 5300 rpm (Stock)
Torque:
250 lb-ft @ 3200 rpm (Stock)
Redline:
6500 rpm
Fuel System
Fuel Delivery:
Electronic Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline, premium recommended (91 octane or higher)
Fuel Injectors:
High-flow injectors required for moderate tuning
Engine Management
ECU Type:
Factory ECU, often remapped or replaced for tuning
🔧 Transmission
Standard
Transmission Type:
Getrag® Heavy Duty Manual (NVT5500)
Number Of Gears:
5-speed manual
Optional
Optional Transmission:
N/A (Exclusively manual transmission)
Features
Gear Ratios:
Specific gear ratios available in the manual
Clutch Type:
Single dry plate, hydraulic actuation
Fluid Specifications
Transmission Fluid Type:
Manual Transmission Fluid (MTF), e.g., Mopar® Manual Transmission Lubricant or equivalent
Fluid Capacity
Transmission Fluid Capacity:
Approximately 2.3 Liters (check manual for exact specification)
📐 Dimensions
Exterior
Length:
174.4 inches (4430 mm)
Width:
67.7 inches (1720 mm)
Height:
55.8 inches (1417 mm)
Wheelbase:
105.1 inches (2670 mm)
Front Track:
58.2 inches (1478 mm)
Rear Track:
58.0 inches (1473 mm)
Weights
Curb Weight:
2995 lbs (1360 kg)
Gross Vehicle Weight Rating:
Approx. 3800 lbs (1724 kg)
Cargo
Trunk Volume:
13.0 cubic feet (368 Liters)
Wheels And Tires
Standard Wheel Size:
17 x 7.5 inches
Standard Tire Size:
205/50R17
Wheel Bolt Pattern:
5 x 100 mm
Wheel Offset:
ET40
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
4-star (2003)
NHTSA Frontal Impact Passenger:
4-star (2003)
IIHS Front Offset Test:
Good (2003-2005)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional Traction Control System (TCS) in later models
Passive Features
Airbags:
Driver and passenger front airbags, optional side airbags
Seatbelts:
Three-point front and rear seat belts with pretensioners
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for CHildren) system
Chassis Enhancements
Structural Reinforcements:
Stiffened chassis and body for improved handling and safety
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional premium audio system with amplifier and subwoofer.
Gauges And Displays:
Includes a boost gauge integrated into the dashboard for real-time turbocharger pressure readings.
Driver Assistance
Cruise Control:
Standard cruise control
Remote Keyless Entry:
Available remote keyless entry system
Connectivity
Auxiliary Input:
N/A (Standard models did not feature aux input; aftermarket solutions exist)
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000-5,000 miles (5,000-8,000 km) or 6 months, depending on driving conditions. Use synthetic oil for best protection.
Oil Filter Replacement:
At every oil change
Engine Air Filter:
Inspect every 7,500 miles, replace as needed (more frequently in dusty conditions)
Spark Plugs:
Recommended replacement every 30,000-60,000 miles (check manual for specific type and gap)
Coolant Flush:
Every 30,000 miles or 2 years
Brake Fluid Flush:
Every 2 years or 30,000 miles
Timing Belt Replacement:
Every 60,000-100,000 miles (CRITICAL component, replacement recommended with tensioner and idler pulleys)
Fluid Specifications
Engine Oil Type:
SAE 5W-40 Synthetic Recommended (check manual for exact spec)
Engine Oil Capacity:
4.5 Quarts (4.3 Liters) with filter
Coolant Type:
HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, Mopar® OAT or equivalent
Power Steering Fluid:
ATF+4® or Mopar® Power Steering Fluid
Known Issues
Common Problems Engine:
Cracked cylinder head (especially on early models and heavily tuned cars), turbo oil feed line restrictions, piston ring wear, exhaust manifold cracking, fuel injector clogging.
Common Problems Transmission:
Bearing failures in the Getrag transmission, clutch wear, synchro ring issues.
Common Problems Suspension:
Worn control arm bushings, premature failure of front struts, rear axle mount bushings.
Common Problems Electrical:
Faulty crank position sensor, intermittent gauge cluster issues, power window regulator failures.
Common Problems Turbo:
Wastegate actuator issues, turbo bearing wear from oil starvation or contamination, boost leaks from aging vacuum lines and couplers.
Maintenance Notes
Tuning Considerations:
Many owners modify these vehicles. The manual is crucial for understanding stock components before modifications. Be aware of potential stress on stock parts with increased boost and power.
📚 Vehicle History
Brand Heritage
Dodge Performance Legacy:
Dodge has a long history of performance vehicles, particularly with its 'SRT' (Street and Racing Technology) division, aiming to create accessible performance cars.
Model Evolution
Neon Generations:
The Neon SRT-4 is part of the second generation of the Dodge Neon, which debuted for the 2000 model year. The SRT-4 variant was introduced for 2003 as a performance halo model.
Srt Division Impact:
The SRT-4 was one of the early successful products from the newly formed SRT division, demonstrating their ability to transform a mainstream compact car into a formidable performance machine.
Production
Manufacturing Location:
Belvidere Assembly Plant, Illinois, USA
Production Volume:
Approximately 20,000 units produced across 2003-2005 model years.
🏆 Awards & Recognition
Recognitions
Car And Driver Best:
Named to Car and Driver's '10Best' list for 2004, recognizing its outstanding performance and value.
Motorsport Achievements:
While not officially supported, the SRT-4 became a popular choice for grassroots motorsports, autocross, and drag racing due to its affordability and tuning potential.
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