Dodge Neon SX 2.0 & SRT-4 2000-2005 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Dodge Model: Neon Generation Codes: Second Generation (PL) Trim Levels Covered: SX 2.0, SRT-4 Model Years: 2000, 2001, 2002, 2003, 2004, 2005 👋 Introduction Market Position Vehicle Class: Compact Car (Economy/Performance variants) Target Audience: DIY enthusiasts, independent repair shops, owners seeking detailed knowledge Competitive Analysis Competitors 2000S: Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier, Mitsubishi Lancer Key Features Variant Distinction: SX 2.0 (standard model) vs. SRT-4 (high-performance turbocharged variant) Manual Advantage: Provides factory-level repair information for both standard and performance variants 📋 Manual Details Coverage Areas Diagnostic Procedures: Extensive troubleshooting guides, DTC code interpretation, system diagnostics Repair Procedures: Step-by-step instructions for all mechanical, electrical, and body components Maintenance Schedules: Regular service intervals for oil changes, fluid checks, filter replacements, and inspections Technical Specifications: Torque values, fluid capacities, clearances, electrical schematics, component data Body And Frame: Body panel removal/installation, chassis repair, glass replacement, interior trim Powertrain: Engine, transmission, driveline, exhaust system repairs and diagnostics Chassis: Suspension, steering, braking system overhaul and diagnostics Electrical System: Wiring diagrams, component testing, lighting, HVAC controls, power accessories, PCM/ECU diagnostics Page Count Estimated Pages: Hundreds (specific count not provided, but described as comprehensive) Manual Type Type: Factory Service Repair Workshop Manual Purpose: Repair, servicing, and troubleshooting Language Primary Language: English Format Digital Format: PDF Download Accessibility: Downloadable to computer, tablet, smartphone Compatibility: Windows and MAC compatible Licensing Usage Rights: Unlimited use, no expiry dates, can be used on multiple devices Version Type: Full, unrestricted version Printing Print Capability: Print single pages or entire manual 📖 Manual Coverage Systems Covered Engine Management: Fuel injection, ignition system, emissions control, engine mechanicals (2.0L SOHC, 2.0L DOHC Turbocharged) Transmission Manual: Clutch system, gear shifting mechanisms, internal component repair Transmission Automatic: Gearbox overhaul, hydraulic control, torque converter service Drivetrain: CV joints, drive axles, differential (if applicable) Suspension Front: MacPherson struts, control arms, sway bars, wheel bearings Suspension Rear: Independent rear suspension components, shock absorbers Steering: Power steering system, steering column, tie rod ends, rack and pinion Brakes Front: Disc brake components, calipers, pads, rotors Brakes Rear: Disc or drum brake components, calipers, pads, rotors, parking brake Anti Lock Braking System: ABS modulator, wheel speed sensors, control module diagnostics Wheels And Tires: Tire specifications, wheel torque, balancing and alignment procedures HVAC System: Air conditioning, heating, ventilation controls, blower motor, refrigerant handling Instrument Panel And Gauges: Cluster removal, gauge testing, warning lights Lighting System: Headlights, taillights, interior lighting, fog lights, bulb replacement Audio System: Radio, speakers, antenna, amplifier installation and troubleshooting Power Accessories: Power windows, power locks, mirrors, sunroof operation and repair Safety Systems: Airbag system, seat belt mechanisms, SRS module diagnostics Procedures Included Scheduled Maintenance: Oil change intervals, filter replacements, spark plug changes, belt inspections Engine Repair: Head gasket replacement, piston/ring service, valve train adjustments, timing belt/chain replacement Turbocharger Service: SRT-4 specific turbocharger inspection, repair, and replacement procedures Transmission Rebuild: Complete disassembly, inspection, and reassembly of manual and automatic transmissions Brake System Overhaul: Brake pad/rotor replacement, caliper rebuilding, brake line flushing and bleeding Suspension Component Replacement: Strut replacement, bushing replacement, ball joint service Electrical Troubleshooting: Diagnosing circuit faults, sensor testing, actuator checks Wiring Diagram Interpretation: Detailed schematics for all vehicle electrical systems Body Panel Replacement: Fender, door, hood, trunk lid removal and installation Interior Trim Removal: Dashboard, door panels, center console disassembly and reassembly Technical Depth Depth Level: Comprehensive (from basic maintenance to complete engine/transmission rebuilds) Illustrations: Detailed photos and exploded diagrams Diagnostic Tools Usage: Guidance on using diagnostic equipment (implied by DTC coverage) 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text within PDF (standard for professional manuals) Print Quality Print Options: High-quality printing of individual pages or the entire document Binding Type Binding: Not Applicable (Digital PDF) Paper Type Paper Quality: Not Applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Sx20 Engine Type: Inline 4-cylinder, SOHC (Single Overhead Camshaft) Displacement: 2.0 Liters (1996 cc) Fuel Delivery: Multi-point Fuel Injection Bore X Stroke: 87.5 mm x 83.0 mm Compression Ratio: 9.8:1 Horsepower Sx20: 132 hp @ 6000 rpm (approx.) Torque Sx20: 130 lb-ft @ 4500 rpm (approx.) Primary Engine Srt4 Engine Type: Inline 4-cylinder, DOHC (Double Overhead Camshaft), Turbocharged Displacement: 2.0 Liters (1996 cc) Fuel Delivery: Multi-point Fuel Injection (with larger injectors for turbo) Turbocharger Model: Garrett GT28RS (or similar Mitsubishi turbo in later models) Boost Pressure: 15-18 psi (approx.) Horsepower Srt4: 200-230 hp @ 5800 rpm (depending on year/spec) Torque Srt4: 220-250 lb-ft @ 3200-4400 rpm (depending on year/spec) Fuel System Fuel Type: Unleaded Gasoline Fuel Pump Type: Electric, in-tank 🔧 Transmission Standard Sx20 Type: 5-Speed Manual Optional Sx20 Type: 4-Speed Automatic Standard Srt4 Type: 6-Speed Manual (Getrag) Features Clutch Type: Hydraulically actuated, single dry plate (upgradeable for SRT-4) Fluid Type Manual Transmission Fluid: API GL-4, SAE 75W-90 (refer to manual for specific Chrysler/Mopar part numbers) Automatic Transmission Fluid: Chrysler ATF+4 (or...

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Type: Car

Vendor:

Sku: 475432

Collections: ALL Dodge

Availability: In stock

Tags: 2000 2001 2002 2003 2004 2005 Car Cars Dodge Neon SX 2.0 SRT-4 SX

Product variants

Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Generation Codes:

Second Generation (PL)

Trim Levels Covered:

SX 2.0, SRT-4

Model Years:

2000, 2001, 2002, 2003, 2004, 2005

👋 Introduction

Market Position

Vehicle Class:

Compact Car (Economy/Performance variants)

Target Audience:

DIY enthusiasts, independent repair shops, owners seeking detailed knowledge

Competitive Analysis

Competitors 2000S:

Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier, Mitsubishi Lancer

Key Features

Variant Distinction:

SX 2.0 (standard model) vs. SRT-4 (high-performance turbocharged variant)

Manual Advantage:

Provides factory-level repair information for both standard and performance variants

📋 Manual Details

Coverage Areas

Diagnostic Procedures:

Extensive troubleshooting guides, DTC code interpretation, system diagnostics

Repair Procedures:

Step-by-step instructions for all mechanical, electrical, and body components

Maintenance Schedules:

Regular service intervals for oil changes, fluid checks, filter replacements, and inspections

Technical Specifications:

Torque values, fluid capacities, clearances, electrical schematics, component data

Body And Frame:

Body panel removal/installation, chassis repair, glass replacement, interior trim

Powertrain:

Engine, transmission, driveline, exhaust system repairs and diagnostics

Chassis:

Suspension, steering, braking system overhaul and diagnostics

Electrical System:

Wiring diagrams, component testing, lighting, HVAC controls, power accessories, PCM/ECU diagnostics

Page Count

Estimated Pages:

Hundreds (specific count not provided, but described as comprehensive)

Manual Type

Type:

Factory Service Repair Workshop Manual

Purpose:

Repair, servicing, and troubleshooting

Language

Primary Language:

English

Format

Digital Format:

PDF Download

Accessibility:

Downloadable to computer, tablet, smartphone

Compatibility:

Windows and MAC compatible

Licensing

Usage Rights:

Unlimited use, no expiry dates, can be used on multiple devices

Version Type:

Full, unrestricted version

Printing

Print Capability:

Print single pages or entire manual

📖 Manual Coverage

Systems Covered

Engine Management:

Fuel injection, ignition system, emissions control, engine mechanicals (2.0L SOHC, 2.0L DOHC Turbocharged)

Transmission Manual:

Clutch system, gear shifting mechanisms, internal component repair

Transmission Automatic:

Gearbox overhaul, hydraulic control, torque converter service

Drivetrain:

CV joints, drive axles, differential (if applicable)

Suspension Front:

MacPherson struts, control arms, sway bars, wheel bearings

Suspension Rear:

Independent rear suspension components, shock absorbers

Steering:

Power steering system, steering column, tie rod ends, rack and pinion

Brakes Front:

Disc brake components, calipers, pads, rotors

Brakes Rear:

Disc or drum brake components, calipers, pads, rotors, parking brake

Anti Lock Braking System:

ABS modulator, wheel speed sensors, control module diagnostics

Wheels And Tires:

Tire specifications, wheel torque, balancing and alignment procedures

HVAC System:

Air conditioning, heating, ventilation controls, blower motor, refrigerant handling

Instrument Panel And Gauges:

Cluster removal, gauge testing, warning lights

Lighting System:

Headlights, taillights, interior lighting, fog lights, bulb replacement

Audio System:

Radio, speakers, antenna, amplifier installation and troubleshooting

Power Accessories:

Power windows, power locks, mirrors, sunroof operation and repair

Safety Systems:

Airbag system, seat belt mechanisms, SRS module diagnostics

Procedures Included

Scheduled Maintenance:

Oil change intervals, filter replacements, spark plug changes, belt inspections

Engine Repair:

Head gasket replacement, piston/ring service, valve train adjustments, timing belt/chain replacement

Turbocharger Service:

SRT-4 specific turbocharger inspection, repair, and replacement procedures

Transmission Rebuild:

Complete disassembly, inspection, and reassembly of manual and automatic transmissions

Brake System Overhaul:

Brake pad/rotor replacement, caliper rebuilding, brake line flushing and bleeding

Suspension Component Replacement:

Strut replacement, bushing replacement, ball joint service

Electrical Troubleshooting:

Diagnosing circuit faults, sensor testing, actuator checks

Wiring Diagram Interpretation:

Detailed schematics for all vehicle electrical systems

Body Panel Replacement:

Fender, door, hood, trunk lid removal and installation

Interior Trim Removal:

Dashboard, door panels, center console disassembly and reassembly

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to complete engine/transmission rebuilds)

Illustrations:

Detailed photos and exploded diagrams

Diagnostic Tools Usage:

Guidance on using diagnostic equipment (implied by DTC coverage)

📊 Manual Specifications

File Format

Format:

Searchability:

Likely searchable text within PDF (standard for professional manuals)

Print Quality

Print Options:

High-quality printing of individual pages or the entire document

Binding Type

Binding:

Not Applicable (Digital PDF)

Paper Type

Paper Quality:

Not Applicable (Digital PDF)

⚙️ Engine Specifications

Primary Engine Sx20

Engine Type:

Inline 4-cylinder, SOHC (Single Overhead Camshaft)

Displacement:

2.0 Liters (1996 cc)

Fuel Delivery:

Multi-point Fuel Injection

Bore X Stroke:

87.5 mm x 83.0 mm

Compression Ratio:

9.8:1

Horsepower Sx20:

132 hp @ 6000 rpm (approx.)

Torque Sx20:

130 lb-ft @ 4500 rpm (approx.)

Primary Engine Srt4

Engine Type:

Inline 4-cylinder, DOHC (Double Overhead Camshaft), Turbocharged

Displacement:

2.0 Liters (1996 cc)

Fuel Delivery:

Multi-point Fuel Injection (with larger injectors for turbo)

Turbocharger Model:

Garrett GT28RS (or similar Mitsubishi turbo in later models)

Boost Pressure:

15-18 psi (approx.)

Horsepower Srt4:

200-230 hp @ 5800 rpm (depending on year/spec)

Torque Srt4:

220-250 lb-ft @ 3200-4400 rpm (depending on year/spec)

Fuel System

Fuel Type:

Unleaded Gasoline

Fuel Pump Type:

Electric, in-tank

🔧 Transmission

Standard Sx20

Type:

5-Speed Manual

Optional Sx20

Type:

4-Speed Automatic

Standard Srt4

Type:

6-Speed Manual (Getrag)

Features

Clutch Type:

Hydraulically actuated, single dry plate (upgradeable for SRT-4)

Fluid Type

Manual Transmission Fluid:

API GL-4, SAE 75W-90 (refer to manual for specific Chrysler/Mopar part numbers)

Automatic Transmission Fluid:

Chrysler ATF+4 (or equivalent)

📐 Dimensions

Exterior Length

Overall Length:

Approx. 174 inches (4420 mm)

Exterior Width

Overall Width:

Approx. 67.4 inches (1712 mm)

Exterior Height

Overall Height:

Approx. 54.1 inches (1374 mm)

Wheelbase

Wheelbase:

Approx. 104.1 inches (2644 mm)

Weights

Curb Weight Sx20:

Approx. 2700 - 2850 lbs (1225 - 1293 kg)

Curb Weight Srt4:

Approx. 2950 - 3050 lbs (1338 - 1383 kg)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Acceptable (for early models, check specific year for full ratings)

IIHS Side Impact:

Marginal to Good (depending on year and specific tests)

Active Features

Available on most models, standard on SRT-4

Traction Control:

Available on some later models/trims

Passive Features

Airbags Front:

Driver and Passenger airbags standard

Airbags Side:

Optional side-impact airbags on some models

Seatbelts:

3-point front and rear seat belts, pretensioners

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player with optional subwoofer and amplifier (Infinity system on some trims)

Display:

Basic digital or analog displays for radio and climate controls

Driver Assistance

Cruise Control:

Standard on most models

Keyless Entry:

Available on higher trims or as an option

Connectivity

Auxiliary Input:

Not standard; aftermarket solutions typically required

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000-7,500 miles or 6-12 months, depending on oil type and driving conditions (refer to manual for precise interval)

Engine Oil Filter:

Replace with every oil change

Engine Air Filter:

Inspect every 15,000 miles, replace as needed or every 30,000 miles

Spark Plugs:

Approx. 60,000-100,000 miles (depending on plug type, e.g., platinum or iridium)

Coolant Flush:

Every 30,000-60,000 miles or 2-4 years

Transmission Fluid Change:

Manual: Inspect regularly, change if contaminated. Automatic: Every 30,000-60,000 miles.

Brake Fluid Flush:

Every 2-3 years or 30,000 miles

Fluid Specifications

Engine Oil Capacity:

4.5 quarts (4.3 Liters) with filter for 2.0L SOHC; 5.0 quarts (4.7 Liters) with filter for 2.0L DOHC Turbocharged (verify with manual)

Engine Oil Viscosity:

SAE 5W-30 or 10W-30 (API Service SG, SH, or SJ certified)

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) or OAT (Organic Acid Technology) compatible coolant, typically 50/50 mix with distilled water.

Power Steering Fluid:

ATF+4 or specified Mopar power steering fluid

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Engine 20 Sx:

Occasional head gasket failures, intake manifold gasket leaks, oil consumption

Engine Srt4:

Clutch wear due to performance driving, turbocharger seal leaks, piston ring land failures under extreme conditions, spark plug fouling.

Suspension:

Worn control arm bushings, premature strut failure, wheel bearing noise

Electrical:

Faulty window regulators, issues with power lock actuators, intermittent gauge cluster problems

HVAC:

Blend door actuator failures, refrigerant leaks

📚 Vehicle History

Brand Heritage

Manufacturer:

Dodge (division of Chrysler Corporation, later DaimlerChrysler)

Model Evolution

First Generation:

1995-1999

Second Generation Launch:

Model year 2000

Facelift:

Minor styling updates during the 2000-2005 lifecycle

Srt-4 Introduction:

Introduced for the 2003 model year, offering significant performance upgrades

Production

Production Plant:

Belvidere Assembly Plant, Illinois, USA

Production End

Final Model Year:

2005 (production continued briefly into 2006 for some markets)

🏆 Awards & Recognition

Recognitions

Performance Awards:

SRT-4 variant often praised by automotive publications for its performance value and handling characteristics in its class.

Segment Recognition:

Neon was a significant player in the compact car segment, offering competitive pricing and practical design.