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Chrysler Dodge Neon 2004 Factory Service Repair Manual

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Basic Information Identification Make: Chrysler Model: Dodge Neon Year: 2004 Codes Chassis Code: PL Introduction Market Position Segment: Compact car Target Audience: DIY mechanics, professional automotive technicians, and vehicle owners seeking in-depth repair knowledge. Competitive Analysis Key Competitors 2004: Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier, Nissan Sentra. Key Features Value Proposition: Provides authoritative, factory-level repair and maintenance information to accurately service the vehicle, saving time and money. Manual Details Coverage Areas General Coverage: Complete official factory service and repair information for the 2004 Chrysler/Dodge Neon. Page Count Estimated Page Count: Hundreds of pages (actual count varies by specific manual version) Manual Type Manual Type: Factory Service Manual (FSM) Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, and overhaul procedures for all engine variants. Transmission: Service and repair of both manual and automatic transmission systems. Brakes: Complete coverage of hydraulic, anti-lock braking systems (ABS) and parking brake. Suspension Steering: Front and rear suspension, steering gear, power steering system, and wheel alignment. Electrical: Wiring diagrams, component testing, charging system, ignition system, lighting, and accessories. Body Chassis: Body panel removal/installation, interior trim, door mechanisms, safety restraints, and chassis components. Heating Ventilation Air Conditioning: HVAC system operation, diagnostics, and repair. Exhaust System: Catalytic converter, mufflers, and exhaust pipe repair and replacement. Procedures Included Maintenance: Scheduled maintenance procedures and intervals. Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting, and diagnostic flowcharts. Repair: Step-by-step repair instructions for all major vehicle systems. Installation: Procedures for replacing major components and accessories. Specifications: Torque specifications, clearances, and other critical measurements. Technical Depth Depth: Comprehensive, covering basic maintenance to complex engine and transmission overhauls. Manual Specifications File Format File Type: PDF Searchability: Typically searchable text within the PDF for efficient information retrieval. Print Quality Printability: Designed to be fully printable, allowing users to print the entire manual or specific sections. Binding Type Binding: N/A (Digital PDF Format) Paper Type Paper: N/A (Digital PDF Format) Engine Specifications Primary Engine Engine Code: EDZ (2.0L SOHC I4) Engine Displacement: 1996 cc (122 cu in) Bore X Stroke: 87.5 mm x 83.0 mm (3.44 in x 3.27 in) Compression Ratio: 9.3:1 Fuel Delivery: Multi-point fuel injection (MPI) Performance Horsepower: 132 hp @ 5600 rpm (approx.) Torque: 130 lb-ft @ 4000 rpm (approx.) Fuel System Fuel Type: Unleaded gasoline Engine Management Ignition System: Distributorless ignition system (DIS) Emission Control: Catalytic converter, Oxygen sensors (O2S), Exhaust Gas Recirculation (EGR) system (where applicable). Transmission Standard Transmission Type: 4-speed Automatic Transaxle (41TE) Optional Transmission Type: 5-speed Manual Transaxle (NVT550) Features Automatic Features: Electronic pressure control, torque converter lock-up. Manual Features Clutch Type: Hydraulic actuation. Fluid Specifications Automatic Fluid Type: ATF+4 (Chrysler Material Standard MS-9602) Manual Fluid Type: API GL-4, SAE 75W-90 gear oil. Dimensions Exterior Wheelbase: 104.2 inches (2647 mm) Length: 174.4 inches (4430 mm) Width: 67.5 inches (1715 mm) Height: 55.5 inches (1410 mm) Interior Front Headroom: 39.4 inches (1001 mm) Rear Legroom: 33.6 inches (853 mm) Cargo Trunk Volume: 13.1 cu ft (approx.) Weights Curb Weight: 2700 - 2900 lbs (approx., depending on configuration) Gross Vehicle Weight Rating: Varies by specific model and configuration. Safety Features Ratings NHTSA Driver Front Impact: Likely 4-star (based on typical ratings for vehicles of this era and class) NHTSA Passenger Front Impact: Likely 4-star (based on typical ratings for vehicles of this era and class) Active Features ABS: Optional Anti-lock Braking System (ABS) available on some trims. Traction Control: Rarely standard, may have been an option on higher trims. Passive Features Airbags: Driver and front passenger airbags standard. Seat Belts: Three-point seat belts for all occupants, pretensioners for front seats. Technology Features Infotainment Audio System: Standard AM/FM stereo with cassette player. Optional CD player and premium sound systems available. Display: Basic analog gauges and digital odometer. No central infotainment screen. Driver Assistance Cruise Control: Optional on most trims. Connectivity Bluetooth: Not available. Usb Port: Not available. Maintenance Service Intervals Oil Change Interval: Every 7,500 miles or 6 months, whichever comes first (with synthetic oil; 3,000 miles with conventional). Air Filter Replacement: Every 30,000 miles or as needed based on inspection. Spark Plug Replacement: Every 100,000 miles (use of appropriate platinum or iridium plugs required). Coolant Flush: Every 30,000 miles or 2 years. Transmission Fluid Change: Automatic: Every 60,000 miles. Manual: Inspect periodically, change if contaminated. Fluid Specifications Engine Oil Type: SAE 5W-30 (API Service SG or higher, meeting Chrysler MS-6395). Coolant Type: Mopar Antifreeze/Coolant (AF) 5/10X Concentrate (Blue) or equivalent meeting Chrysler MS-7170. Brake Fluid Type: DOT 3. Known Issues Engine: Oil leaks from valve cover gasket, head gasket failures (especially on early models/poorly maintained units), occasional ignition coil failures. Transmission: Automatic transmission clutch wear, potential failure of the input/output speed sensors. Electrical: Window regulator failures, power lock actuator issues, dashboard warning light illumination due to sensor faults. Suspension: Premature wear of...
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Chrysler Dodge Neon 2004 Factory Service Repair Manual
Basic Information
Identification
Make: Chrysler
Model: Dodge Neon
Year: 2004
Codes
Chassis Code: PL
Introduction
Market Position
Segment: Compact car
Target Audience: DIY mechanics, professional automotive technicians, and vehicle owners seeking in-depth repair knowledge.
Competitive Analysis
Key Competitors 2004: Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier, Nissan Sentra.
Key Features
Value Proposition: Provides authoritative, factory-level repair and maintenance information to accurately service the vehicle, saving time and money.
Manual Details
Coverage Areas
General Coverage: Complete official factory service and repair information for the 2004 Chrysler/Dodge Neon.
Page Count
Estimated Page Count: Hundreds of pages (actual count varies by specific manual version)
Manual Type
Manual Type: Factory Service Manual (FSM)
Language
Language: English
Format
Format: PDF Download
Manual Coverage
Systems Covered
Engine: Detailed diagnostics, repair, and overhaul procedures for all engine variants.
Transmission: Service and repair of both manual and automatic transmission systems.
Brakes: Complete coverage of hydraulic, anti-lock braking systems (ABS) and parking brake.
Suspension Steering: Front and rear suspension, steering gear, power steering system, and wheel alignment.
Electrical: Wiring diagrams, component testing, charging system, ignition system, lighting, and accessories.
Body Chassis: Body panel removal/installation, interior trim, door mechanisms, safety restraints, and chassis components.
Heating Ventilation Air Conditioning: HVAC system operation, diagnostics, and repair.
Exhaust System: Catalytic converter, mufflers, and exhaust pipe repair and replacement.
Procedures Included
Maintenance: Scheduled maintenance procedures and intervals.
Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting, and diagnostic flowcharts.
Repair: Step-by-step repair instructions for all major vehicle systems.
Installation: Procedures for replacing major components and accessories.
Specifications: Torque specifications, clearances, and other critical measurements.
Technical Depth
Depth: Comprehensive, covering basic maintenance to complex engine and transmission overhauls.
Manual Specifications
File Format
File Type: PDF
Searchability: Typically searchable text within the PDF for efficient information retrieval.
Print Quality
Printability: Designed to be fully printable, allowing users to print the entire manual or specific sections.
Binding Type
Binding: N/A (Digital PDF Format)
Paper Type
Paper: N/A (Digital PDF Format)
Engine Specifications
Primary Engine
Engine Code: EDZ (2.0L SOHC I4)
Engine Displacement: 1996 cc (122 cu in)
Bore X Stroke: 87.5 mm x 83.0 mm (3.44 in x 3.27 in)
Compression Ratio: 9.3:1
Fuel Delivery: Multi-point fuel injection (MPI)
Performance
Horsepower: 132 hp @ 5600 rpm (approx.)
Torque: 130 lb-ft @ 4000 rpm (approx.)
Fuel System
Fuel Type: Unleaded gasoline
Engine Management
Ignition System: Distributorless ignition system (DIS)
Emission Control: Catalytic converter, Oxygen sensors (O2S), Exhaust Gas Recirculation (EGR) system (where applicable).
Transmission
Standard
Transmission Type: 4-speed Automatic Transaxle (41TE)
Optional
Transmission Type: 5-speed Manual Transaxle (NVT550)
Features
Automatic Features: Electronic pressure control, torque converter lock-up.
Manual Features
Clutch Type: Hydraulic actuation.
Fluid Specifications
Automatic Fluid Type: ATF+4 (Chrysler Material Standard MS-9602)
Manual Fluid Type: API GL-4, SAE 75W-90 gear oil.
Dimensions
Exterior
Wheelbase: 104.2 inches (2647 mm)
Length: 174.4 inches (4430 mm)
Width: 67.5 inches (1715 mm)
Height: 55.5 inches (1410 mm)
Interior
Front Headroom: 39.4 inches (1001 mm)
Rear Legroom: 33.6 inches (853 mm)
Cargo
Trunk Volume: 13.1 cu ft (approx.)
Weights
Curb Weight: 2700 - 2900 lbs (approx., depending on configuration)
Gross Vehicle Weight Rating: Varies by specific model and configuration.
Safety Features
Ratings
NHTSA Driver Front Impact: Likely 4-star (based on typical ratings for vehicles of this era and class)
NHTSA Passenger Front Impact: Likely 4-star (based on typical ratings for vehicles of this era and class)
Active Features
ABS: Optional Anti-lock Braking System (ABS) available on some trims.
Traction Control: Rarely standard, may have been an option on higher trims.
Passive Features
Airbags: Driver and front passenger airbags standard.
Seat Belts: Three-point seat belts for all occupants, pretensioners for front seats.
Technology Features
Infotainment
Audio System: Standard AM/FM stereo with cassette player. Optional CD player and premium sound systems available.
Display: Basic analog gauges and digital odometer. No central infotainment screen.
Driver Assistance
Cruise Control: Optional on most trims.
Connectivity
Bluetooth: Not available.
Usb Port: Not available.
Maintenance
Service Intervals
Oil Change Interval: Every 7,500 miles or 6 months, whichever comes first (with synthetic oil; 3,000 miles with conventional).
Air Filter Replacement: Every 30,000 miles or as needed based on inspection.
Spark Plug Replacement: Every 100,000 miles (use of appropriate platinum or iridium plugs required).
Coolant Flush: Every 30,000 miles or 2 years.
Transmission Fluid Change: Automatic: Every 60,000 miles. Manual: Inspect periodically, change if contaminated.
Fluid Specifications
Engine Oil Type: SAE 5W-30 (API Service SG or higher, meeting Chrysler MS-6395).
Coolant Type: Mopar Antifreeze/Coolant (AF) 5/10X Concentrate (Blue) or equivalent meeting Chrysler MS-7170.
Brake Fluid Type: DOT 3.
Known Issues
Engine: Oil leaks from valve cover gasket, head gasket failures (especially on early models/poorly maintained units), occasional ignition coil failures.
Transmission: Automatic transmission clutch wear, potential failure of the input/output speed sensors.
Electrical: Window regulator failures, power lock actuator issues, dashboard warning light illumination due to sensor faults.
Suspension: Premature wear of control arm bushings, ball joints, and tie rod ends. Rear axle beam bushings can also degrade.
Vehicle History
Brand Heritage
Chrysler Positioning: Chrysler Corporation (later DaimlerChrysler) positioned Dodge as its performance-oriented division, with Neon as a sporty and affordable compact.
Model Evolution
Second Generation: The 2004 model year represents the second generation of the Neon (PL platform), which debuted for the 2000 model year. Significant styling and engineering updates occurred throughout its lifecycle.
Production
Production Period: 1994-2005 (First Gen: 1994-1999; Second Gen: 2000-2005)
Manufacturing Location: Belvidere, Illinois, USA.
Awards & Recognition
Recognitions
Automobile Magazine All Star: The first-generation Neon (prior to 2000) was recognized as an Automobile Magazine All-Star in 1995.
Crash Test Ratings: The second-generation Neon received mixed crash test results from the IIHS and NHTSA, typical for vehicles of its era, with the manual advising owners to consult specific ratings for their vehicle's configuration.
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