2002 Neon PL Dodge Chrysler Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Neon Year: 2002 Platform: PL Codes Chassis Code: PL 👋 Introduction Market Position Segment: Compact car, economy car. Target Audience: Budget-conscious consumers, first-time car buyers, young drivers. Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier, Nissan Sentra. Key Features Design: Distinctive styling (often polarizing), practical hatchback and sedan body styles. Value Proposition: Affordable purchase price, decent fuel economy, relatively simple mechanicals. Manual Value Utility: Essential tool for DIY mechanics and professional technicians to maintain, diagnose, and repair the 2002 Dodge Neon PL. 📋 Manual Details Coverage Areas Languages: English Manual Type: Factory Service Manual / Repair Manual Page Count Estimated Pages: 1000+ Format Format: Printed 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, valve train, pistons, connecting rods, crankshaft, lubrication system, cooling system, timing system, fuel system. Engine Performance: Engine management, ignition system, fuel injection, emissions control, engine diagnostics. Transmission Manual: Clutch, gearbox operation, gear selection, synchronizers, bearings, seals, linkages, fluid specifications. Transmission Automatic: Torque converter, planetary gear sets, hydraulic control system, valve body, transmission control module (TCM), fluid specifications. Drivetrain: Front-wheel drive system, half-shafts, CV joints, differential, wheel bearings. Brakes: Front and rear brake systems (disc/drum or disc/disc), hydraulic system, master cylinder, brake booster, ABS (Anti-lock Braking System), parking brake, brake fluid specifications. Steering: Power steering system, steering column, steering gear/rack and pinion, tie rod ends, power steering fluid specifications. Suspension: Front suspension (struts, control arms, ball joints, sway bar), rear suspension (torsion beam, trailing arms, shocks/struts), wheel alignment specifications. Electrical System: Battery, charging system (alternator), starting system (starter motor), fuses, relays, wiring diagrams, lighting systems, ignition switch. Body And Trim: Exterior body panels, interior trim components, door mechanisms, glass, seals, bumpers, hood, trunk lid. HVAC: Heating, ventilation, and air conditioning (HVAC) system, blower motor, evaporator, condenser, refrigerant, cabin air filter. Safety Systems: Airbag system, seat belts, child seat anchorages (LATCH/ISOFIX). Procedures Included Routine Maintenance: Oil changes, fluid checks and top-offs, filter replacements (air, oil, fuel, cabin), spark plug replacement, brake pad inspection. Troubleshooting: Diagnostic procedures, symptom-based troubleshooting guides, common fault diagnosis. Repair Procedures: Step-by-step repair instructions for all major mechanical and electrical components, including engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement, electrical component repair. Diagnostics: On-board diagnostics (OBD-II) codes, diagnostic connector location, scan tool usage, sensor testing, actuator testing, module programming information. Wiring Diagrams: Comprehensive electrical wiring diagrams for all vehicle systems, including power distribution, grounds, sensor circuits, actuator circuits, control modules. Technical Specifications: Torque specifications for fasteners, fluid capacities, gap specifications, measurement data, component tolerances. Technical Depth Depth: Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including in-depth electrical diagnostics and wiring diagrams. 📊 Manual Specifications File Format File Type: Printed Book Print Quality Quality: High-quality paper, clear and legible text and diagrams, durable binding. Binding Type Binding: Comb binding or stitched binding for lay-flat use in a workshop environment. Paper Type Paper: Durable, often coated paper to withstand grease and workshop conditions. ⚙️ Engine Specifications Primary Engine Engine 1 Displacement: 1.6 Liters Engine 1 Configuration: Inline 4-cylinder (I4), Single Overhead Cam (SOHC) Engine 1 Horsepower: Approx. 106 hp @ 6000 rpm (varies slightly by market/specific version) Engine 1 Torque: Approx. 106 lb-ft @ 3000 rpm (varies slightly by market/specific version) Engine 1 Fuel System: Multi-point Fuel Injection (MPI) Secondary Engine Engine 2 Displacement: 2.0 Liters Engine 2 Configuration: Inline 4-cylinder (I4), Single Overhead Cam (SOHC) Engine 2 Horsepower: Approx. 115 hp @ 5600 rpm (varies slightly by market/specific version) Engine 2 Torque: Approx. 127 lb-ft @ 3000 rpm (varies slightly by market/specific version) Engine 2 Fuel System: Multi-point Fuel Injection (MPI) Performance Engine Cooling: Pressurized coolant system with thermostat-controlled fan. Fuel System Fuel Type: Unleaded gasoline Fuel Tank Capacity: Approx. 13.0 gallons 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission (Getrag MD-75 for some variants, Aisin AX-15 for others) Optional Transmission Type: 4-speed Automatic Transmission (Chrysler 41TE) Features Automatic Transmission Control: Electronic control with torque converter lock-up. Fluid Type Manual Transmission Fluid: API GL-3 or GL-4 SAE 75W-90 or 80W-90 (refer to manual for specific recommendations). Automatic Transmission Fluid: Chrysler ATF+4 (Mopar Part Number 05013457AA or equivalent). 📐 Dimensions Exterior Wheelbase: Approx. 104.3 inches Length: Approx. 174.9 inches (Sedan) / 170.1 inches (Hatchback) Width: Approx. 67.4 inches Height: Approx. 53.8 inches (Sedan) / 53.3 inches (Hatchback) Weights Curb Weight: Approx. 2,600 - 2,800 lbs (depending on engine and transmission) Cargo Trunk Volume: Approx. 14.0 cu ft (Sedan) Hatchback Cargo Volume: Approx. 20.1 cu ft (seats up) / 46.7 cu ft (seats down) 🛡️ Safety Features Ratings NHTSA Frontal Driver Rating: 4 Stars (for 2002 models) NHTSA Frontal Passenger Rating: 4 Stars (for 2002 models) IIHS Moderate Overlap Frontal Offset: Good (for some earlier generations, check specific reports for 2002) Active Features ABS: Available Anti-lock Braking System...

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Sku: 333294

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Tags: 2002 Car Chrysler Dodge Chrysler Marine Misc Neon PL Outboard Engines

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Year:

Platform:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact car, economy car.

Target Audience:

Budget-conscious consumers, first-time car buyers, young drivers.

Competitive Analysis

Key Competitors:

Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier, Nissan Sentra.

Key Features

Design:

Distinctive styling (often polarizing), practical hatchback and sedan body styles.

Value Proposition:

Affordable purchase price, decent fuel economy, relatively simple mechanicals.

Manual Value

Utility:

Essential tool for DIY mechanics and professional technicians to maintain, diagnose, and repair the 2002 Dodge Neon PL.

📋 Manual Details

Coverage Areas

Languages:

English

Manual Type:

Factory Service Manual / Repair Manual

Page Count

Estimated Pages:

1000+

Format

Format:

Printed

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, valve train, pistons, connecting rods, crankshaft, lubrication system, cooling system, timing system, fuel system.

Engine Performance:

Engine management, ignition system, fuel injection, emissions control, engine diagnostics.

Transmission Manual:

Clutch, gearbox operation, gear selection, synchronizers, bearings, seals, linkages, fluid specifications.

Transmission Automatic:

Torque converter, planetary gear sets, hydraulic control system, valve body, transmission control module (TCM), fluid specifications.

Drivetrain:

Front-wheel drive system, half-shafts, CV joints, differential, wheel bearings.

Brakes:

Front and rear brake systems (disc/drum or disc/disc), hydraulic system, master cylinder, brake booster, ABS (Anti-lock Braking System), parking brake, brake fluid specifications.

Steering:

Power steering system, steering column, steering gear/rack and pinion, tie rod ends, power steering fluid specifications.

Suspension:

Front suspension (struts, control arms, ball joints, sway bar), rear suspension (torsion beam, trailing arms, shocks/struts), wheel alignment specifications.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), fuses, relays, wiring diagrams, lighting systems, ignition switch.

Body And Trim:

Exterior body panels, interior trim components, door mechanisms, glass, seals, bumpers, hood, trunk lid.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, blower motor, evaporator, condenser, refrigerant, cabin air filter.

Safety Systems:

Airbag system, seat belts, child seat anchorages (LATCH/ISOFIX).

Procedures Included

Routine Maintenance:

Oil changes, fluid checks and top-offs, filter replacements (air, oil, fuel, cabin), spark plug replacement, brake pad inspection.

Troubleshooting:

Diagnostic procedures, symptom-based troubleshooting guides, common fault diagnosis.

Repair Procedures:

Step-by-step repair instructions for all major mechanical and electrical components, including engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement, electrical component repair.

Diagnostics:

On-board diagnostics (OBD-II) codes, diagnostic connector location, scan tool usage, sensor testing, actuator testing, module programming information.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems, including power distribution, grounds, sensor circuits, actuator circuits, control modules.

Technical Specifications:

Torque specifications for fasteners, fluid capacities, gap specifications, measurement data, component tolerances.

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including in-depth electrical diagnostics and wiring diagrams.

📊 Manual Specifications

File Format

File Type:

Printed Book

Print Quality

Quality:

High-quality paper, clear and legible text and diagrams, durable binding.

Binding Type

Binding:

Comb binding or stitched binding for lay-flat use in a workshop environment.

Paper Type

Paper:

Durable, often coated paper to withstand grease and workshop conditions.

⚙️ Engine Specifications

Primary Engine

Engine 1 Displacement:

1.6 Liters

Engine 1 Configuration:

Inline 4-cylinder (I4), Single Overhead Cam (SOHC)

Engine 1 Horsepower:

Approx. 106 hp @ 6000 rpm (varies slightly by market/specific version)

Engine 1 Torque:

Approx. 106 lb-ft @ 3000 rpm (varies slightly by market/specific version)

Engine 1 Fuel System:

Multi-point Fuel Injection (MPI)

Secondary Engine

Engine 2 Displacement:

2.0 Liters

Engine 2 Configuration:

Inline 4-cylinder (I4), Single Overhead Cam (SOHC)

Engine 2 Horsepower:

Approx. 115 hp @ 5600 rpm (varies slightly by market/specific version)

Engine 2 Torque:

Approx. 127 lb-ft @ 3000 rpm (varies slightly by market/specific version)

Engine 2 Fuel System:

Multi-point Fuel Injection (MPI)

Performance

Engine Cooling:

Pressurized coolant system with thermostat-controlled fan.

Fuel System

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

Approx. 13.0 gallons

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transmission (Getrag MD-75 for some variants, Aisin AX-15 for others)

Optional

Transmission Type:

4-speed Automatic Transmission (Chrysler 41TE)

Features

Automatic Transmission Control:

Electronic control with torque converter lock-up.

Fluid Type

Manual Transmission Fluid:

API GL-3 or GL-4 SAE 75W-90 or 80W-90 (refer to manual for specific recommendations).

Automatic Transmission Fluid:

Chrysler ATF+4 (Mopar Part Number 05013457AA or equivalent).

📐 Dimensions

Exterior

Wheelbase:

Approx. 104.3 inches

Length:

Approx. 174.9 inches (Sedan) / 170.1 inches (Hatchback)

Width:

Approx. 67.4 inches

Height:

Approx. 53.8 inches (Sedan) / 53.3 inches (Hatchback)

Weights

Curb Weight:

Approx. 2,600 - 2,800 lbs (depending on engine and transmission)

Cargo

Trunk Volume:

Approx. 14.0 cu ft (Sedan)

Hatchback Cargo Volume:

Approx. 20.1 cu ft (seats up) / 46.7 cu ft (seats down)

🛡️ Safety Features

Ratings

NHTSA Frontal Driver Rating:

4 Stars (for 2002 models)

NHTSA Frontal Passenger Rating:

4 Stars (for 2002 models)

IIHS Moderate Overlap Frontal Offset:

Good (for some earlier generations, check specific reports for 2002)

Active Features

Available Anti-lock Braking System (ABS) on some trims.

Passive Features

Airbags:

Standard front driver and passenger airbags. Side airbags may be optional on some trims.

Seat Belts:

3-point front seat belts with pretensioners, 3-point rear seat belts.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD or cassette player. Speaker configurations vary by trim level.

Display:

Basic dashboard displays for speed, tachometer, fuel, temperature. No integrated navigation or advanced displays in base models.

Driver Assistance

Cruise Control:

Available as an option on most trims.

Traction Control:

Not commonly available on this generation Neon.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles or 3-6 months, depending on oil type and driving conditions (refer to manual for specifics).

Air Filter Replacement:

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

Spark Plug Replacement:

Approx. 60,000-100,000 miles (depending on spark plug type, e.g., copper vs. platinum/iridium).

Transmission Fluid Change:

Manual: Check condition; Automatic: Every 30,000-60,000 miles or as recommended by dealer/manual.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 API SN/SP or ILSAC GF-6A (refer to owner's manual for precise recommendation and viscosity options based on temperature).

Engine Coolant:

Chrysler OAT (Organic Additive Technology) HOAT (Hybrid Organic Additive Technology) 50/50 mixture with distilled water. Mopar Antifreeze/Coolant (e.g., PN 05103534AA).

Brake Fluid:

DOT 3 or DOT 4 (refer to manual for specific type, typically DOT 3 is specified).

Power Steering Fluid:

ATF+3 or ATF+4 (Chrysler specification, refer to manual).

Known Issues

Engine Performance:

Oil leaks (valve cover gasket, oil pan gasket), exhaust manifold cracks, intake manifold gasket leaks, potential for piston slap or oil consumption in high-mileage engines.

Transmission:

Clutch wear (manual), transmission solenoid issues or torque converter clutch (TCC) lock-up problems (automatic).

Suspension And Steering:

Worn control arm bushings, worn ball joints, tie rod end wear, power steering pump whine or leaks.

Electrical System:

Alternator failure, starter motor issues, window regulator failures, door lock actuator failures, power mirror motor failures.

HVAC:

HVAC blower motor failure, evaporator leaks, refrigerant leaks.

Body:

Rust on body panels (especially around wheel wells and rocker panels), door hinge wear, trunk lid alignment.

📚 Vehicle History

Brand Heritage

Manufacturer:

Dodge (a division of Chrysler Corporation, later DaimlerChrysler).

Model Evolution

First Generation:

First generation (1995-2005) launched as a bold and distinctive design to appeal to younger buyers. Known for its unique styling and sporty aspirations.

Second Generation:

The 2002 model falls within the first generation. Minor updates and refinements were made throughout this period.

Production

Production Years:

1995-2005 (First Generation)

Assembly Locations:

Belvidere, Illinois, USA

🏆 Awards & Recognition

Recognitions

Design Award:

While not winning specific major awards for styling, the Neon's distinct design was a talking point and aimed to differentiate it in a crowded segment. It was considered a more youthful and visually striking option than some competitors.

Ratings

Consumer Reports:

Consumer Reports often noted average to below-average reliability for the Neon, particularly in its earlier years, with common issues related to the powertrain, suspension, and electrical systems. However, this manual provides the means to address and rectify these issues.