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Dodge Neon 2000 2001 2002 2003 2004 2005 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Neon Generation: Second Generation (PL) Codes Chassis Code: PL Platform: Chrysler PL platform 👋 Introduction Market Position Segment: Compact Car Target Audience: Economy-conscious buyers, young drivers, performance enthusiasts (SRT-4). Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier. Unique Selling Points: Sporty styling, surprisingly spacious interior for its class, affordable pricing, potent SRT-4 variant. Key Features Body Styles: 4-door Sedan, 2-door Coupe. Performance Variant: Neon SRT-4 was a standout with its turbocharged engine and sport-tuned chassis. 📋 Manual Details Coverage Areas Years Covered: 2000, 2001, 2002, 2003, 2004, 2005 Trim Levels Covered: All trim levels (e.g., ES, SXT, ACR, R/T) Engine Variants Covered: 2.0L SOHC (16V), 2.0L DOHC (16V) SRT-4 Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine repair, overhaul, tuning, diagnostics for both SOHC and DOHC engines. Engine Performance: Includes specifications and procedures for the high-performance SRT-4 variant. Fuel System: Fuel injection, fuel pump, injectors, pressure regulator, evaporative emission control (EVAP). Cooling System: Radiator, water pump, thermostat, cooling fans, coolant specifications. Ignition System: Spark plugs, coils, ignition timing, distributorless ignition system (DIS). Exhaust System: Catalytic converter, mufflers, pipes, oxygen sensors. Transmission Manual: Clutch system, gear shifting mechanisms, internal components, fluid specifications. Transmission Automatic: Torque converter, valve body, internal gears, fluid specifications, electronic controls. Drivetrain: Front-wheel drive (FWD) system, CV joints, drive axles, differential. Suspension: Front struts, rear shock absorbers, springs, control arms, bushings, alignment specifications. Steering: Power steering system, steering rack, tie rods, steering column, fluid specifications. Brakes Hydraulic: Brake master cylinder, brake lines, calipers, wheel cylinders, brake fluid specifications. Brakes Anti-Lock: ABS control module, wheel speed sensors, hydraulic control unit (HCU), diagnostic procedures. Body Frame And Structure: Unibody construction, frame repair, body panel replacement, structural integrity. Exterior: Doors, hood, trunk, bumpers, glass, mirrors, exterior trim, lighting. Interior: Seats, dashboard, door panels, headliner, carpeting, climate controls, trim components. Electrical System Power: Battery, alternator, charging system, starter motor, power distribution. Electrical System Lighting: Headlights, taillights, interior lights, fog lights, wiring diagrams for lighting circuits. Electrical System Accessories: Wipers, horn, power windows, power locks, mirrors, audio system wiring. Instrument Panel And Gauges: Speedometer, tachometer, fuel gauge, temperature gauge, warning lights, diagnostic trouble codes (DTCs). Climate Control: HVAC system, air conditioning (A/C), heater core, blower motor, refrigerant R-134a. Safety Restraints: Airbag system (SRS), seat belts, pretensioners, diagnostic and replacement procedures. Security System: Factory alarm system, immobilizer, keyless entry, component location and troubleshooting. Diagnostics: OBD-II (On-Board Diagnostics II) troubleshooting, DTC retrieval, sensor data analysis. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks, tire rotations, spark plug replacement. Component Removal And Installation: Detailed steps for removing and reinstalling virtually all mechanical and electrical components. Troubleshooting Guides: Systematic approach to diagnosing and resolving common and uncommon problems. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems, crucial for electrical diagnostics. Rebuilding Procedures: Complete overhaul procedures for engines and transmissions. Calibration And Adjustment: Procedures for aligning sensors, setting timing, and adjusting systems. Technical Depth Diagnostic Capability: Advanced diagnostics, including sensor readings, actuator testing, and signal tracing. Repair Scope: From basic fluid changes and filter replacements to complete engine and transmission rebuilds. Special Tools: Lists and descriptions of specialized tools required for specific repair procedures. Specifications And Tolerances: Precise measurements, torque values, clearances, and other critical specifications for all components. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text content for quick access to information. Illustration Quality: High-resolution, clear, step-by-step illustrations and diagrams. Print Quality Printability: Printable pages for in-shop use. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Base Engine Displacement: 2.0 Liters Base Engine Configuration: Inline-4 (I4) Base Engine Valvetrain: SOHC 16-Valve (132 hp @ 5600 rpm, 130 lb-ft @ 4000 rpm) Performance Optional Engine Displacement: 2.0 Liters (SRT-4) Optional Engine Configuration: Inline-4 (I4) Turbocharged Optional Engine Valvetrain: DOHC 16-Valve (200 hp @ 5300 rpm, 225 lb-ft @ 2400 rpm) Fuel System Fuel Type: Unleaded Gasoline Fuel Delivery: Electronic Fuel Injection (EFI) Engine Control Module: Chrysler Engine Control Module (ECM) 🔧 Transmission Standard Transmission Type: 5-Speed Manual Optional Transmission Type: 4-Speed Automatic (42LE) Features Clutch Type: Hydraulically Actuated Single Dry Plate Clutch Transmission Fluid Manual: Mopar Manual Transmission Lubricant (or equivalent) Transmission Fluid Automatic: Chrysler ATF+4 (or equivalent) 📐 Dimensions Exterior Length Sedan: 175.7 inches (4463 mm) Length Coupe: 171.5 inches (4356 mm) Width: 67.4 inches (1712 mm) Height Sedan: 54.5 inches (1384 mm) Height Coupe: 53.4 inches (1356 mm) Wheelbase: 104.1 inches (2644 mm) Wheel Bolt Pattern: 4x100mm Tire Size Standard: 185/70R14 Tire Size Performance: 205/50R17 (SRT-4) Cargo Trunk Volume Sedan: 13.5 cu ft (382 L) Trunk Volume Coupe: 10.5 cu ft (297 L) Weights Curb Weight...
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Dodge Neon 2000 2001 2002 2003 2004 2005 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Neon
Generation:
Second Generation (PL)
Codes
Chassis Code:
PL
Platform:
Chrysler PL platform
👋 Introduction
Market Position
Segment:
Compact Car
Target Audience:
Economy-conscious buyers, young drivers, performance enthusiasts (SRT-4).
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier.
Unique Selling Points:
Sporty styling, surprisingly spacious interior for its class, affordable pricing, potent SRT-4 variant.
Key Features
Body Styles:
4-door Sedan, 2-door Coupe.
Performance Variant:
Neon SRT-4 was a standout with its turbocharged engine and sport-tuned chassis.
📋 Manual Details
Coverage Areas
Years Covered:
2000, 2001, 2002, 2003, 2004, 2005
Trim Levels Covered:
All trim levels (e.g., ES, SXT, ACR, R/T)
Engine Variants Covered:
2.0L SOHC (16V), 2.0L DOHC (16V) SRT-4
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine repair, overhaul, tuning, diagnostics for both SOHC and DOHC engines.
Engine Performance:
Includes specifications and procedures for the high-performance SRT-4 variant.
Fuel System:
Fuel injection, fuel pump, injectors, pressure regulator, evaporative emission control (EVAP).
Cooling System:
Radiator, water pump, thermostat, cooling fans, coolant specifications.
Ignition System:
Spark plugs, coils, ignition timing, distributorless ignition system (DIS).
Exhaust System:
Catalytic converter, mufflers, pipes, oxygen sensors.
Transmission Manual:
Clutch system, gear shifting mechanisms, internal components, fluid specifications.
Transmission Automatic:
Torque converter, valve body, internal gears, fluid specifications, electronic controls.
Drivetrain:
Front-wheel drive (FWD) system, CV joints, drive axles, differential.
Suspension:
Front struts, rear shock absorbers, springs, control arms, bushings, alignment specifications.
Steering:
Power steering system, steering rack, tie rods, steering column, fluid specifications.
Brakes Hydraulic:
Brake master cylinder, brake lines, calipers, wheel cylinders, brake fluid specifications.
Brakes Anti-Lock:
ABS control module, wheel speed sensors, hydraulic control unit (HCU), diagnostic procedures.
Body Frame And Structure:
Unibody construction, frame repair, body panel replacement, structural integrity.
Exterior:
Doors, hood, trunk, bumpers, glass, mirrors, exterior trim, lighting.
Interior:
Seats, dashboard, door panels, headliner, carpeting, climate controls, trim components.
Electrical System Power:
Battery, alternator, charging system, starter motor, power distribution.
Electrical System Lighting:
Headlights, taillights, interior lights, fog lights, wiring diagrams for lighting circuits.
Electrical System Accessories:
Wipers, horn, power windows, power locks, mirrors, audio system wiring.
Instrument Panel And Gauges:
Speedometer, tachometer, fuel gauge, temperature gauge, warning lights, diagnostic trouble codes (DTCs).
Climate Control:
HVAC system, air conditioning (A/C), heater core, blower motor, refrigerant R-134a.
Safety Restraints:
Airbag system (SRS), seat belts, pretensioners, diagnostic and replacement procedures.
Security System:
Factory alarm system, immobilizer, keyless entry, component location and troubleshooting.
Diagnostics:
OBD-II (On-Board Diagnostics II) troubleshooting, DTC retrieval, sensor data analysis.
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, fluid checks, tire rotations, spark plug replacement.
Component Removal And Installation:
Detailed steps for removing and reinstalling virtually all mechanical and electrical components.
Troubleshooting Guides:
Systematic approach to diagnosing and resolving common and uncommon problems.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems, crucial for electrical diagnostics.
Rebuilding Procedures:
Complete overhaul procedures for engines and transmissions.
Calibration And Adjustment:
Procedures for aligning sensors, setting timing, and adjusting systems.
Technical Depth
Diagnostic Capability:
Advanced diagnostics, including sensor readings, actuator testing, and signal tracing.
Repair Scope:
From basic fluid changes and filter replacements to complete engine and transmission rebuilds.
Special Tools:
Lists and descriptions of specialized tools required for specific repair procedures.
Specifications And Tolerances:
Precise measurements, torque values, clearances, and other critical specifications for all components.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text content for quick access to information.
Illustration Quality:
High-resolution, clear, step-by-step illustrations and diagrams.
Print Quality
Printability:
Printable pages for in-shop use.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Base Engine Displacement:
2.0 Liters
Base Engine Configuration:
Inline-4 (I4)
Base Engine Valvetrain:
SOHC 16-Valve (132 hp @ 5600 rpm, 130 lb-ft @ 4000 rpm)
Performance
Optional Engine Displacement:
2.0 Liters (SRT-4)
Optional Engine Configuration:
Inline-4 (I4) Turbocharged
Optional Engine Valvetrain:
DOHC 16-Valve (200 hp @ 5300 rpm, 225 lb-ft @ 2400 rpm)
Fuel System
Fuel Type:
Unleaded Gasoline
Fuel Delivery:
Electronic Fuel Injection (EFI)
Engine Control Module:
Chrysler Engine Control Module (ECM)
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual
Optional
Transmission Type:
4-Speed Automatic (42LE)
Features
Clutch Type:
Hydraulically Actuated Single Dry Plate Clutch
Transmission Fluid Manual:
Mopar Manual Transmission Lubricant (or equivalent)
Transmission Fluid Automatic:
Chrysler ATF+4 (or equivalent)
📐 Dimensions
Exterior
Length Sedan:
175.7 inches (4463 mm)
Length Coupe:
171.5 inches (4356 mm)
Width:
67.4 inches (1712 mm)
Height Sedan:
54.5 inches (1384 mm)
Height Coupe:
53.4 inches (1356 mm)
Wheelbase:
104.1 inches (2644 mm)
Wheel Bolt Pattern:
4x100mm
Tire Size Standard:
185/70R14
Tire Size Performance:
205/50R17 (SRT-4)
Cargo
Trunk Volume Sedan:
13.5 cu ft (382 L)
Trunk Volume Coupe:
10.5 cu ft (297 L)
Weights
Curb Weight Base:
2600-2800 lbs (1179-1270 kg)
Curb Weight Srt-4:
2975 lbs (1350 kg)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
Good (2001 Model Year)
NHTSA Frontal Impact Passenger:
Good (2001 Model Year)
IIHS Frontal Offset:
Acceptable (2000-2003 Model Years)
Active Features
ABS:
Available on most trims, standard on SRT-4.
Traction Control:
Available on some trims, standard on SRT-4.
Passive Features
Airbags Front:
Driver and Passenger front airbags standard.
Airbags Side:
Optional side-impact airbags on some trims.
Seat Belts:
3-point seat belts with pretensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player (optional cassette), 4-6 speaker configurations.
Display:
Basic digital or analog displays for climate control and audio.
Driver Assistance
Cruise Control:
Available on most trims.
Parking Assist:
Not available.
Connectivity
Bluetooth:
Not available.
Usb Port:
Not available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 6 months, whichever comes first (synthetic oil recommended).
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on driving conditions.
Spark Plug Replacement Sohc:
Every 100,000 miles (platinum or iridium recommended).
Spark Plug Replacement DOHc Srt-4:
Every 30,000-45,000 miles (performance spark plugs required).
Coolant Flush:
Every 30,000 miles or 3 years.
Transmission Fluid Change Auto:
Every 30,000 - 60,000 miles.
Transmission Fluid Change Manual:
Inspect every 30,000 miles, change as needed (typically 60,000-100,000 miles).
Fluid Specifications
Engine Oil Type Viscosity:
SAE 5W-30 (API certified) for most conditions. Consult manual for extreme temperature variations.
Engine Oil Capacity:
4.5 US quarts (4.3 L) with filter (2.0L SOHC/DOHC).
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant (Green) or equivalent.
Brake Fluid Type:
DOT 3 (or DOT 4 for improved performance).
Power Steering Fluid:
Chrysler Power Steering Fluid (or equivalent).
Known Issues
Engine:
Oil leaks from valve cover and oil pan gaskets, intake manifold gasket failure (common on early models), piston ring wear leading to oil consumption.
Transmission:
Automatic transmission shifting problems, clutch wear in manual transmissions.
Suspension:
Premature wear of front struts and sway bar end links.
Electrical:
Faulty power window regulators, intermittent HVAC blower motor operation, ABS sensor failures.
Body:
Rust formation on wheel wells, rocker panels, and door bottoms, especially in corrosive climates.
Srt-4 Specific:
Clutch issues under heavy use, turbocharger wastegate rattle, fuel injector failure.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
USA (Chrysler Corporation, later DaimlerChrysler)
Model Evolution
First Generation:
1995-1999
Second Generation Introduction:
2000 (PL Platform)
Mid-Cycle Refresh:
Facelift in 2003 with revised styling and interior updates.
Performance Variant Introduction:
SRT-4 introduced for the 2003 model year, quickly gaining a cult following.
Production
Production Period:
2000-2005
Assembly Location:
Belvidere, Illinois, USA
Discontinuation:
Dodge Neon was discontinued after the 2005 model year, replaced by the Dodge Caliber.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
Named to Car and Driver's 10Best list in 1995 and 1996 for its first generation, setting a precedent for value and performance in its class.
Srt-4 Reputation:
Highly regarded in the tuner community and by automotive journalists for its performance-per-dollar value.
Ratings
Initial Quality Surveys:
Generally rated average to below average in initial quality surveys compared to Japanese competitors, reflecting some build quality concerns common in its segment at the time.
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