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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Tags: 2003 2004 2005 Car Cars Dodge Misc Neon SRT4

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Description

🏷️ 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:

👋 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:

🛡️ 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

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.