2004 Chrysler PL SRT-4 and Neon Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Chrysler Model: Neon Trim: SRT-4 Year: 2004 Codes Chassis Code: PT Engine Code: ECC (2.4L Turbocharged) 👋 Introduction Market Position Market Niche: Performance compact sedan, targeting the tuner and enthusiast market. Competitors: Subaru WRX, Mitsubishi Lancer Evolution (though often positioned below these), Honda Civic Si, Ford Focus SVT. Key Features Performance Focus: Significantly upgraded engine and suspension compared to standard Neon models, making it a purpose-built performance variant. Value Proposition: Offered a potent turbocharged engine and sporty handling at a more accessible price point than many import performance rivals. Significance Srt Division: Represents Chrysler's Street and Racing Technology (SRT) division's foray into the compact performance segment. 📋 Manual Details Coverage Areas Primary Coverage: 2004 Chrysler PL SRT-4 and Neon Secondary Coverage: General Neon models of the second generation (PL platform) Page Count Estimated Page Count: 1000+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: 2.4L DOHC Turbocharged (ECC), including disassembly, assembly, inspection, and component testing Transmission: 5-Speed Manual Transmission (Getrag/Chrysler T850/NVT-3500), including clutch, linkage, and internal components Drivetrain: Front Wheel Drive (FWD) system, including axles, CV joints, and differential Suspension: Front independent suspension (MacPherson struts), Rear independent suspension (multi-link), including components, alignment, and adjustments Steering: Power-assisted rack and pinion steering system Brakes: Front and Rear disc brakes, ABS system, including hydraulic components, pads, rotors, and bleeding procedures Cooling System: Radiator, fan, water pump, thermostat, hoses, and coolant specifications Fuel System: Fuel tank, pump, filter, injectors, fuel pressure regulation, and Turbocharger fuel delivery Exhaust System: Exhaust manifold, catalytic converter, muffler, and turbo exhaust components Electrical System: Battery, charging system (alternator), starting system, ignition system, lighting, and wiring diagrams Engine Control Module ECM: ECU/PCM diagnosis, sensors (MAP, O2, Crankshaft, Camshaft, Knock), actuators, and powertrain control strategies Body And Trim: Exterior panels, interior trim, doors, windows, locks, seats, and body sealing HVAC: Heating, Ventilation, and Air Conditioning system, including compressor, refrigerant, and climate controls Safety Systems: Airbag system, seat belts, and ABS system Procedures Included Maintenance: Routine maintenance tasks, fluid changes, filter replacements, spark plug service, belt inspections Troubleshooting: Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, DTC (Diagnostic Trouble Code) interpretation Repair: Step-by-step repair instructions for all major vehicle components and systems Overhaul: Complete engine and transmission overhaul procedures Rebuild: Component rebuild procedures for specific parts like turbochargers, alternators, starter motors Diagnosis: Detailed diagnostic routines for electrical and mechanical systems Specifications And Tolerances: Torque specifications, measurement tolerances, and clearance specifications for all critical components Wiring Diagrams: Comprehensive electrical wiring diagrams for all vehicle circuits Technical Depth Depth: Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchable: Yes (typically text-searchable PDF) Printable: Yes Print Quality Quality: High resolution, suitable for clear reproduction of diagrams and text Binding Type Binding: N/A (Digital Product) Paper Type Paper Type: N/A (Digital Product) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, DOHC, 16-valve, turbocharged Engine Code: ECC Displacement: 2.4 Liters (2429 cc) Performance Horsepower: 205 hp @ 5800 RPM Torque: 230 lb-ft @ 4200 RPM Redline: 6500 RPM Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Denso turbocharger Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Turbocharger Turbo Model: Garrett T25 or similar (specific manufacturer varied slightly, often specified as Mitsubishi TD04 or Garrett GT2554R in aftermarket upgrades) Engine Internals Pistons: Forged pistons (a key upgrade for durability) Connecting Rods: Forged connecting rods (a key upgrade for durability) 🔧 Transmission Standard Transmission Type: 5-Speed Manual Transmission Model: Getrag/Chrysler T850 (often referred to as NVG-3500 in some documentation) Features Gear Ratios: Specific ratios available in manual: 1st: 3.46, 2nd: 2.14, 3rd: 1.45, 4th: 1.06, 5th: 0.82, Reverse: 3.06 Final Drive Ratio: 4.05 Clutch Type: Hydraulically actuated, single dry plate Optional Optional Transmission: None (SRT-4 exclusively manual) 📐 Dimensions Exterior Length: 170.1 inches (4320 mm) Width: 67.0 inches (1702 mm) Height: 55.4 inches (1407 mm) Wheelbase: 104.3 inches (2649 mm) Front Track: 58.5 inches (1486 mm) Rear Track: 58.5 inches (1486 mm) Weights Curb Weight: 2950 lbs (1338 kg) Gross Vehicle Weight Rating: 3750 lbs (1701 kg) Cargo Trunk Capacity: 13.1 cubic feet (371 liters) 🛡️ Safety Features Ratings NHTSA Frontal Driver: 4/5 Stars (for 2004 Neon) NHTSA Frontal Passenger: 4/5 Stars (for 2004 Neon) IIHS Moderate Overlap Frontal Offset: Acceptable (for 2004 Neon) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Available Traction Control System (TCS) Passive Features Airbags: Standard front airbags (driver and passenger), optional side curtain airbags Seat Belts: 3-point front and rear seat belts, pretensioners for front seats Body Structure: Reinforced passenger safety cage 💡 Technology Features Infotainment Audio System: AM/FM stereo with CD player, optional Infinity sound system....
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, DTC (Diagnostic Trouble Code) interpretation
Repair:
Step-by-step repair instructions for all major vehicle components and systems
Overhaul:
Complete engine and transmission overhaul procedures
Rebuild:
Component rebuild procedures for specific parts like turbochargers, alternators, starter motors
Diagnosis:
Detailed diagnostic routines for electrical and mechanical systems
Specifications And Tolerances:
Torque specifications, measurement tolerances, and clearance specifications for all critical components
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all vehicle circuits
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchable:
Yes (typically text-searchable PDF)
Printable:
Yes
Print Quality
Quality:
High resolution, suitable for clear reproduction of diagrams and text
Binding Type
Binding:
N/A (Digital Product)
Paper Type
Paper Type:
N/A (Digital Product)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, turbocharged
Engine Code:
ECC
Displacement:
2.4 Liters (2429 cc)
Performance
Horsepower:
205 hp @ 5800 RPM
Torque:
230 lb-ft @ 4200 RPM
Redline:
6500 RPM
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Denso turbocharger
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Turbocharger
Turbo Model:
Garrett T25 or similar (specific manufacturer varied slightly, often specified as Mitsubishi TD04 or Garrett GT2554R in aftermarket upgrades)
Engine Internals
Pistons:
Forged pistons (a key upgrade for durability)
Connecting Rods:
Forged connecting rods (a key upgrade for durability)
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual
Transmission Model:
Getrag/Chrysler T850 (often referred to as NVG-3500 in some documentation)
Features
Gear Ratios:
Specific ratios available in manual: 1st: 3.46, 2nd: 2.14, 3rd: 1.45, 4th: 1.06, 5th: 0.82, Reverse: 3.06
Final Drive Ratio:
4.05
Clutch Type:
Hydraulically actuated, single dry plate
Optional
Optional Transmission:
None (SRT-4 exclusively manual)
📐 Dimensions
Exterior
Length:
170.1 inches (4320 mm)
Width:
67.0 inches (1702 mm)
Height:
55.4 inches (1407 mm)
Wheelbase:
104.3 inches (2649 mm)
Front Track:
58.5 inches (1486 mm)
Rear Track:
58.5 inches (1486 mm)
Weights
Curb Weight:
2950 lbs (1338 kg)
Gross Vehicle Weight Rating:
3750 lbs (1701 kg)
Cargo
Trunk Capacity:
13.1 cubic feet (371 liters)
🛡️ Safety Features
Ratings
NHTSA Frontal Driver:
4/5 Stars (for 2004 Neon)
NHTSA Frontal Passenger:
4/5 Stars (for 2004 Neon)
IIHS Moderate Overlap Frontal Offset:
Acceptable (for 2004 Neon)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS)
Passive Features
Airbags:
Standard front airbags (driver and passenger), optional side curtain airbags
Seat Belts:
3-point front and rear seat belts, pretensioners for front seats
Body Structure:
Reinforced passenger safety cage
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional Infinity sound system.
Display:
Basic digital clock and radio display. No integrated navigation or touchscreen.
Driver Assistance
Cruise Control:
Standard cruise control
Connectivity
Auxiliary Input:
Not standard; aftermarket solutions often available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months (whichever comes first), using synthetic oil highly recommended for turbo applications.
Engine Air Filter:
Inspect every 15,000 miles, replace as needed.
Spark Plugs:
Replace every 60,000 miles (specific performance plugs recommended).
Transmission Fluid:
Inspect at 30,000 miles, change typically recommended every 60,000-100,000 miles depending on usage and fluid type.
Coolant Flush:
Every 60,000 miles or 4 years.
Fluid Specifications
Engine Oil:
SAE 0W-40 synthetic oil is often recommended by SRT specialists for its higher viscosity under heat and turbo protection.
Engine Oil Capacity:
4.5 Quarts (4.3 Liters) with filter change
Coolant:
Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically Mopar OAT or equivalent. 50/50 mix with distilled water.
Transmission Fluid:
ATF+4 (for automatic transmission, if applicable to other Neon models, but T850 is manual) - Manual Transmission Fluid (MTF) specifications for the T850 are critical and require specific GL-4 rated fluid.
Known Issues
Engine Mounts:
Common failure point, leading to engine movement and vibration. Upgraded mounts are a popular aftermarket solution.
Clutch:
Can wear out prematurely with aggressive driving. Clutch pedal springs can also fail.
Turbocharger:
Oil starvation or contamination can lead to premature failure. Proper maintenance and warm-up/cool-down cycles are crucial.
Fuel Injectors:
Can become clogged over time, affecting performance. Regular use of quality fuel and occasional injector cleaner is beneficial.
Suspension Components:
Worn control arm bushings, ball joints, and strut mounts are common on higher mileage vehicles.
📚 Vehicle History
Brand Heritage
Chrysler Performance:
Chrysler's history in performance tuning and motorsports, though this was a significant step into the compact performance segment.
Model Evolution
Neon Generations:
This manual covers the second generation (PL platform, 2000-2005), with the SRT-4 being the high-performance variant introduced for the 2003 model year.
Production
Manufacturing Location:
Belvidere, Illinois, USA
Production Years Srt4:
2003-2005
🏆 Awards & Recognition
Recognitions
Performance Awards:
Frequently lauded by automotive journalists for its exceptional performance-to-price ratio in its class during its production run.
Import Tuner Magazine:
Often featured and praised in import tuning publications for its modifiability and accessible performance.
Ratings
Car And Driver Rankings:
Praised for its surprising acceleration and handling for its price point.