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Dodge Neon 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Neon Year: 2004 👋 Introduction Market Position Segment: Compact Car / Economy Car Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier Key Features Target Audience: DIYers, Independent Repair Shops, Enthusiasts Manual Advantage: Provides factory-level detail and procedures often missing in aftermarket guides, enabling cost-effective repairs and maintenance. 📋 Manual Details Coverage Areas Primary Coverage: Maintenance, Repair, Diagnostics, Troubleshooting, Electrical Systems, Mechanical Systems, Bodywork, Specifications Engine Variants Covered: 2.0L SOHC (420A) and 2.0L DOHC (optional on some models/trims like ACR) Trim Levels Covered: All major trim levels including SE, ES, ACR, R/T (if applicable for 2004, though R/T was more prominent in earlier years) Page Count Estimated Page Count: 1500-2000+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine (2.0L), Transmission (Automatic & Manual), Clutch, Drivetrain Components Chassis: Suspension (Front & Rear), Steering, Brakes (Front & Rear Disc/Drum), Wheels, Tires Electrical: Engine Control Module (ECM), Powertrain Control Module (PCM), Body Control Module (BCM), Lighting, Instruments, Audio System, HVAC Controls, Power Accessories (Windows, Locks), Safety Systems (Airbags, ABS) Body And Trim: Exterior Body Panels, Interior Trim, Doors, Hood, Trunk, Glass, Bumpers Procedures Included Maintenance: Oil Change, Filter Replacements, Fluid Checks & Replacements, Spark Plug Service, Belt Inspections & Replacements, Brake Pad & Rotor Replacement, Tire Rotation Diagnostics: OBD-II Diagnostics, DTC Code Interpretation, Component Testing, Symptom-Based Troubleshooting Guides Repair: Engine Rebuild Procedures, Transmission Overhaul, Suspension Component Replacement, Brake System Repair, Electrical Component Replacement, Body Panel Repair Cooling System: Radiator, Water Pump, Thermostat, Hoses, Coolant Flush, Fan Operation Exhaust System: Muffler, Catalytic Converter, Manifold, Oxygen Sensors Fuel System: Fuel Pump, Fuel Filter, Injectors, Fuel Pressure Regulator, EVAP System Lighting And Accessories: Headlights, Taillights, Interior Lights, Power Mirrors, Power Seats (if equipped) Body And Frame: Frame Straightening, Panel Replacement, Door Hinge Adjustment, Lock Cylinder Replacement Electrical Diagnostics: Wiring diagrams, fuse box layouts, component testing for sensors (TPS, MAP, Crankshaft Position, Camshaft Position), actuators (injectors, ignition coils), and control modules. Suspension And Steering Repair: Strut replacement, ball joint service, tie rod end replacement, power steering pump and rack repair. Technical Depth Depth: Comprehensive from basic fluid changes to complete engine and transmission overhauls, including detailed electrical schematics and diagnostic procedures. Diagnostic Tools: Detailed explanations for using OBD-II scanners, multimeter for electrical testing, and specific diagnostic procedures for sensors and actuators. 📊 Manual Specifications File Format Digital Format: Searchable PDF with Bookmarked Sections Print Quality Print Readability: High-resolution scanned pages for clear text and diagrams Binding Type Physical Binding: N/A (Digital Format) Paper Type Physical Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated Inline-4 Engine Code: 420A (132 hp version) / EDZ (150 hp version - ACR trim) Displacement: 2.0 Liters (1996 cc) Valve Train: SOHC 16-valve (420A), DOHC 16-valve (EDZ/420B) Performance Horsepower: 132 hp @ 5600 rpm (Standard), 150 hp @ 6000 rpm (ACR) Torque: 130 lb-ft @ 4000 rpm (Standard), 130 lb-ft @ 4800 rpm (ACR) Fuel System Fuel Delivery: Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Ignition System Type: Distributorless Ignition System (DIS) with Coil-on-Plug 🔧 Transmission Standard Type: 4-Speed Automatic Transaxle Optional Type: 5-Speed Manual Transaxle Features Automatic Modes: Standard Drive, Overdrive (O/D Off) Fluid Specifications Automatic Transmission Fluid: ATF+4 (Mopar) Manual Transmission Fluid: MS-9070 (SAE 75W-90 GL-3/GL-4) 📐 Dimensions Exterior Wheelbase: 104.1 inches (2644 mm) Length: 174.4 inches (4430 mm) Width: 67.4 inches (1712 mm) Height: 54.9 inches (1394 mm) Weights Curb Weight: 2700 - 2900 lbs (approx.) 🛡️ Safety Features Ratings NHTSA Front Impact: 4/5 Stars (Driver/Passenger) NHTSA Side Impact: 4/4 Stars (Front/Rear Passenger) Active Features ABS: Available Anti-lock Braking System (ABS) Passive Features Airbags: Driver and Passenger Front Airbags Seatbelts: Front Pretensioner Seatbelts 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD Player with optional Premium Sound System Display: Basic Digital/Analog Instrument Cluster Driver Assistance Cruise Control: Standard on most trims Connectivity Auxiliary Inputs: None standard; aftermarket solutions available. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-7,500 miles (depending on oil type and driving conditions; consult manual for specifics) Air Filter Replacement: Every 15,000-30,000 miles or as needed Spark Plug Replacement: Every 60,000-100,000 miles (depending on plug type; consult manual) Fluid Specifications Coolant: 50/50 mixture of Mopar Antifreeze/Coolant (MS-7170 or equivalent) and distilled water Brake Fluid: DOT 3 Power Steering Fluid: ATF+4 (Mopar) or equivalent Engine Oil Type: API SN or higher, SAE 5W-30 (or 10W-30 depending on ambient temperature, consult manual) Known Issues Common Failures: Head Gasket Leaks (especially on early 420A engines), Oil Leaks (rear main seal, valve cover gasket), Coil Pack Failures, Alternator Failures, Suspension Bushing Wear Electrical Quirks: Wiring harness issues, power window motor failures, door lock actuator problems Transmission Issues: Automatic transmission hard shifts, manual clutch wear, synchro issues in manual transmissions. Fluid Capacities...
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Dodge Neon 2004 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Neon
Year:
2004
👋 Introduction
Market Position
Segment:
Compact Car / Economy Car
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier
Key Features
Target Audience:
DIYers, Independent Repair Shops, Enthusiasts
Manual Advantage:
Provides factory-level detail and procedures often missing in aftermarket guides, enabling cost-effective repairs and maintenance.
📋 Manual Details
Coverage Areas
Primary Coverage:
Maintenance, Repair, Diagnostics, Troubleshooting, Electrical Systems, Mechanical Systems, Bodywork, Specifications
Engine Variants Covered:
2.0L SOHC (420A) and 2.0L DOHC (optional on some models/trims like ACR)
Trim Levels Covered:
All major trim levels including SE, ES, ACR, R/T (if applicable for 2004, though R/T was more prominent in earlier years)
Page Count
Estimated Page Count:
1500-2000+
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (2.0L), Transmission (Automatic & Manual), Clutch, Drivetrain Components
Chassis:
Suspension (Front & Rear), Steering, Brakes (Front & Rear Disc/Drum), Wheels, Tires
Electrical:
Engine Control Module (ECM), Powertrain Control Module (PCM), Body Control Module (BCM), Lighting, Instruments, Audio System, HVAC Controls, Power Accessories (Windows, Locks), Safety Systems (Airbags, ABS)
Body And Trim:
Exterior Body Panels, Interior Trim, Doors, Hood, Trunk, Glass, Bumpers
Procedures Included
Maintenance:
Oil Change, Filter Replacements, Fluid Checks & Replacements, Spark Plug Service, Belt Inspections & Replacements, Brake Pad & Rotor Replacement, Tire Rotation
Diagnostics:
OBD-II Diagnostics, DTC Code Interpretation, Component Testing, Symptom-Based Troubleshooting Guides
Repair:
Engine Rebuild Procedures, Transmission Overhaul, Suspension Component Replacement, Brake System Repair, Electrical Component Replacement, Body Panel Repair
Cooling System:
Radiator, Water Pump, Thermostat, Hoses, Coolant Flush, Fan Operation
Exhaust System:
Muffler, Catalytic Converter, Manifold, Oxygen Sensors
Fuel System:
Fuel Pump, Fuel Filter, Injectors, Fuel Pressure Regulator, EVAP System
Lighting And Accessories:
Headlights, Taillights, Interior Lights, Power Mirrors, Power Seats (if equipped)
Body And Frame:
Frame Straightening, Panel Replacement, Door Hinge Adjustment, Lock Cylinder Replacement
Electrical Diagnostics:
Wiring diagrams, fuse box layouts, component testing for sensors (TPS, MAP, Crankshaft Position, Camshaft Position), actuators (injectors, ignition coils), and control modules.
Suspension And Steering Repair:
Strut replacement, ball joint service, tie rod end replacement, power steering pump and rack repair.
Technical Depth
Depth:
Comprehensive from basic fluid changes to complete engine and transmission overhauls, including detailed electrical schematics and diagnostic procedures.
Diagnostic Tools:
Detailed explanations for using OBD-II scanners, multimeter for electrical testing, and specific diagnostic procedures for sensors and actuators.
📊 Manual Specifications
File Format
Digital Format:
Searchable PDF with Bookmarked Sections
Print Quality
Print Readability:
High-resolution scanned pages for clear text and diagrams
Binding Type
Physical Binding:
N/A (Digital Format)
Paper Type
Physical Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Inline-4
Engine Code:
420A (132 hp version) / EDZ (150 hp version - ACR trim)
Displacement:
2.0 Liters (1996 cc)
Valve Train:
SOHC 16-valve (420A), DOHC 16-valve (EDZ/420B)
Performance
Horsepower:
132 hp @ 5600 rpm (Standard), 150 hp @ 6000 rpm (ACR)
Torque:
130 lb-ft @ 4000 rpm (Standard), 130 lb-ft @ 4800 rpm (ACR)
Fuel System
Fuel Delivery:
Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Ignition System
Type:
Distributorless Ignition System (DIS) with Coil-on-Plug
🔧 Transmission
Standard
Type:
4-Speed Automatic Transaxle
Optional
Type:
5-Speed Manual Transaxle
Features
Automatic Modes:
Standard Drive, Overdrive (O/D Off)
Fluid Specifications
Automatic Transmission Fluid:
ATF+4 (Mopar)
Manual Transmission Fluid:
MS-9070 (SAE 75W-90 GL-3/GL-4)
📐 Dimensions
Exterior
Wheelbase:
104.1 inches (2644 mm)
Length:
174.4 inches (4430 mm)
Width:
67.4 inches (1712 mm)
Height:
54.9 inches (1394 mm)
Weights
Curb Weight:
2700 - 2900 lbs (approx.)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4/5 Stars (Driver/Passenger)
NHTSA Side Impact:
4/4 Stars (Front/Rear Passenger)
Active Features
ABS:
Available Anti-lock Braking System (ABS)
Passive Features
Airbags:
Driver and Passenger Front Airbags
Seatbelts:
Front Pretensioner Seatbelts
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD Player with optional Premium Sound System
Display:
Basic Digital/Analog Instrument Cluster
Driver Assistance
Cruise Control:
Standard on most trims
Connectivity
Auxiliary Inputs:
None standard; aftermarket solutions available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles (depending on oil type and driving conditions; consult manual for specifics)
Air Filter Replacement:
Every 15,000-30,000 miles or as needed
Spark Plug Replacement:
Every 60,000-100,000 miles (depending on plug type; consult manual)
Fluid Specifications
Coolant:
50/50 mixture of Mopar Antifreeze/Coolant (MS-7170 or equivalent) and distilled water
Brake Fluid:
DOT 3
Power Steering Fluid:
ATF+4 (Mopar) or equivalent
Engine Oil Type:
API SN or higher, SAE 5W-30 (or 10W-30 depending on ambient temperature, consult manual)
Known Issues
Common Failures:
Head Gasket Leaks (especially on early 420A engines), Oil Leaks (rear main seal, valve cover gasket), Coil Pack Failures, Alternator Failures, Suspension Bushing Wear
Electrical Quirks:
Wiring harness issues, power window motor failures, door lock actuator problems
Transmission Issues:
Automatic transmission hard shifts, manual clutch wear, synchro issues in manual transmissions.
Fluid Capacities
Engine Oil Capacity:
4.0 Quarts (3.8 Liters) with filter change
Coolant Capacity:
Approx. 7.0 Quarts (6.6 Liters)
📚 Vehicle History
Brand Heritage
Manufacturer:
Chrysler Corporation (Dodge Division)
Model Evolution
Generation:
Second Generation (1995-2005)
Design Philosophy:
Penned by the renowned Italian design house Pininfarina, the Neon was known for its distinctive styling and sporty appeal in its class.
Production
Manufacturing Plants:
Belvidere, Illinois, USA
🏆 Awards & Recognition
Recognitions
Popular Mechanics Car Of The-Year:
1995 (for the first generation, influencing brand perception)
Ratings
Consumer Reports Reliability:
Generally rated as average to below average for its class, highlighting the importance of thorough maintenance documented in this manual.
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