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Chrysler Neon 2002 2003 2004 2005 Reparatur-Servicehandbuch

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🏷️ Basic Information Identification Make: Chrysler Model: Neon Years: 2002, 2003, 2004, 2005 Codes Chassis Code: PL 👋 Introduction Market Position Vehicle Segment: Compact car / Economy car. Target Audience:...
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Chrysler Neon 2002 2003 2004 2005 Reparatur-Servicehandbuch
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Neon
Years:
2002, 2003, 2004, 2005
Codes
Chassis Code:
PL
👋 Introduction
Market Position
Vehicle Segment:
Compact car / Economy car.
Target Audience:
Budget-conscious consumers seeking reliable, practical transportation.
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier, Nissan Sentra.
Key Features
Design Philosophy:
Penned by François Castaing, aiming for a distinctive, sporty design compared to many competitors of its era.
Value Proposition:
Affordable pricing, fuel efficiency, spacious interior for its class, and surprisingly capable handling.
📋 Manual Details
Coverage Areas
General Coverage:
Comprehensive repair, service, and maintenance for 2002-2005 Chrysler Neon.
Page Count
Estimated Page Count:
1500-2000+ pages (typical for comprehensive factory service manuals).
Manual Type
Manual Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF) - Likely searchable and printable.
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, cooling system, exhaust system, ignition system, starting system, charging system.
Transmission Drivetrain:
Manual transmission (Getrag NV1500/NV3500), Automatic transmission (41TE/42LE), clutch system, axles, driveshafts, differential.
Chassis Suspension Steering:
Front suspension (MacPherson strut), rear suspension (multi-link trailing arm), steering system (power rack and pinion), wheel bearings, alignment specifications.
Brakes:
Front disc brakes, rear drum brakes, anti-lock braking system (ABS), hydraulic system, parking brake.
Electrical Electronics:
Body control module (BCM), engine control module (ECM), lighting, instrument cluster, power windows, power locks, mirrors, horn, audio system, safety systems (airbags).
Climate Control:
Heating, ventilation, and air conditioning (HVAC) system, refrigerant handling, system diagnostics.
Body Exterior Interior:
Body panels, doors, hood, trunk, bumpers, glass, interior trim, seats, upholstery, weatherstripping.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting, fault code interpretations (OBD-II).
Repair Replacement:
Step-by-step instructions for component removal, installation, and overhaul for all major systems.
Diagnostics:
Detailed diagnostic procedures for engine performance, electrical systems, HVAC, and more. Includes wiring diagrams and component locations.
Specifications Data:
Torque specifications, fluid capacities, diagnostic values, alignment angles, electrical resistance values.
Technical Depth
Depth Of Information:
Expert level. Covers everything from basic maintenance to complete engine and transmission rebuilds, complex electrical diagnostics, and bodywork repairs.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Text-searchable (assuming OCR has been applied or it's natively digital).
Print Quality
Printability:
High-resolution, suitable for printing individual pages or sections.
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
SOHC 2.0L (1996cc) I4 - Sirius / OHC
Engine Code Optional:
DOHC 2.0L (1996cc) I4 - ACR / DOHC (Performance variants)
Performance Sohc
Horsepower Sohc:
132 hp @ 5600 rpm
Torque Sohc:
130 lb-ft @ 4000 rpm
Performance Dohc
Horsepower DOHc:
145-150 hp @ 6000-6500 rpm (depending on variant)
Torque DOHc:
135-140 lb-ft @ 4800-5000 rpm
Fuel System
Fuel Delivery:
Sequential Electronic Fuel Injection (SEFI)
Fuel Type:
Unleaded gasoline, 87 octane recommended.
Engine Management
Ignition System:
Distributorless Ignition System (DIS) with coil-on-plug or coil pack configuration.
🔧 Transmission
Standard Transmission
Transmission Type Standard:
5-Speed Manual Transmission (Getrag NV1500/NV3500)
Optional Transmission
Transmission Type Optional:
4-Speed Automatic Transmission (Chrysler 41TE / 42LE)
Features
Transmission Fluid Spec Manual:
API GL-4 gear oil (e.g., Mopar Manual Transmission Lubricant or equivalent).
Transmission Fluid Spec Automatic:
ATF+4 (Chrysler Mopar automatic transmission fluid) or compatible DEXRON III/MERCON.
Clutch
Clutch Type:
Dry single plate, diaphragm spring clutch (for manual transmission).
📐 Dimensions
Exterior
Length:
Approx. 174.4 inches (4429 mm)
Width:
Approx. 67.4 inches (1712 mm)
Height:
Approx. 54.3 inches (1380 mm)
Wheelbase:
Approx. 104.4 inches (2652 mm)
Interior
Passenger Volume:
Approx. 96.0 cu ft (2719 L)
Cargo
Trunk Volume:
Approx. 13.0 cu ft (368 L)
Weights
Curb Weight:
Approx. 2700 - 2900 lbs (1225 - 1315 kg)
Gross Vehicle Weight Rating:
Approx. 3800 - 4000 lbs (1724 - 1814 kg)
Wheels Tires
Wheel Bolt Pattern:
4x100mm
Standard Tire Size:
P185/70R14, P195/60R15 (depending on trim level)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
4-star (for coupes) / 4-star (for sedans) in some testing years.
IIHS Crash Test Ratings:
Generally good frontal impact ratings for its class and era.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) on some trims.
Passive Features
Airbags:
Driver and front passenger airbags standard.
Seatbelts:
Three-point seat belts for all occupants, pretensioners for front seats.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM stereo with CD player and optional cassette player. Upgraded Infinity sound system available on some trims.
Dashboard Features:
Analogue gauges for speedometer, tachometer, fuel level, and coolant temperature. Warning lights for various systems.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Connectivity
Power Accessories:
Power windows, power door locks, and power mirrors available on most trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 6 months (synthetic blend) or 3,750 miles (conventional oil), whichever comes first. Consult manual for exact specification.
Air Filter Replacement:
Inspect every 15,000 miles, replace as needed. Replace every 30,000 miles for optimal performance.
Spark Plug Replacement:
Platinum-tipped spark plugs: 100,000 miles. Standard spark plugs: 30,000 miles. Consult specific engine type.
Coolant Flush:
Every 30,000 miles or 2 years.
Fluid Specifications
Engine Oil Type:
SAE 5W-30, meeting Chrysler Material Standard MS-6395 (API Certified).
Engine Oil Capacity:
4.5 US quarts (4.3 Liters) with filter for 2.0L engine.
Coolant Type:
Mopar Antifreeze/Coolant (Green) or equivalent HOAT (Hybrid Organic Acid Technology) coolant.
Brake Fluid Type:
DOT 3 Brake Fluid.
Known Issues
Common Problem 1:
Head gasket failure (particularly on early models with the DOHC engine), often due to coolant leaks.
Common Problem 2:
Interior trim quality and durability concerns; some plastic components can become brittle.
Common Problem 3:
Power steering pump noise or leaks.
Common Problem 4:
Rear axle bushings can wear out, leading to clunking noises and poor handling.
Common Problem 5:
Window regulators and motors can fail.
📚 Vehicle History
Brand Heritage
Manufacturer History:
Chrysler Corporation, a major American automotive manufacturer with a long history of innovation.
Model Evolution
Generation:
Second generation (PL) of the Chrysler Neon.
Design Changes Second Gen:
Restyled exterior (smoother lines, more integrated bumpers), improved interior ergonomics, and revised suspension tuning compared to the first generation.
Production
Production Period:
Second generation production ran from 2000 to 2006 (model years).
Manufacturing Location:
Belvidere, Illinois, USA.
🏆 Awards & Recognition
Recognitions
Automotive Journal Mentions:
Often cited for its value and sporty styling, though sometimes criticized for interior quality and specific reliability issues compared to Japanese competitors.
Ratings
Consumer Reports Historical:
Consumer Reports ratings varied; typically average to below average in predicted reliability for the powertrain and electrical systems during its run.
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