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2002 DODGE Neon Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Neon Year: 2002 Codes Chassis Code: PL (Second Generation) 👋 Introduction Market Position Segment: Compact car, known for its affordability, sporty handling (especially...
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UGS: 395390
Mots clés: 2002 Car Cars Dodge Misc Neon
2002 DODGE Neon Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Neon
Year:
2002
Codes
Chassis Code:
PL (Second Generation)
👋 Introduction
Market Position
Segment:
Compact car, known for its affordability, sporty handling (especially R/T models), and distinctive styling.
Competitive Analysis
Competitors:
Competed against vehicles like the Honda Civic, Toyota Corolla, Ford Focus, and Chevrolet Cavalier.
Key Features
Strengths:
Good value proposition, agile handling, attractive exterior design, available performance variants.
Weaknesses:
Perceived build quality concerns in some areas, interior materials could be better, reliance on Chrysler/Dodge corporate platforms.
📋 Manual Details
Coverage Areas
Covered Models:
All 2002 Dodge Neon variants (e.g., ES, SXT, R/T)
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
2.0L SOHC (16-valve) and 2.0L DOHC (16-valve) engines, including assembly, disassembly, diagnosis, and repair.
Transmission:
Manual (5-speed) and Automatic (3-speed) transmissions, including removal, installation, internal repairs, and fluid service.
Drivetrain:
Front-wheel drive system, including half-shafts, differential, and related components.
Suspension:
Front McPherson strut and rear independent suspension (multi-link), including shock absorbers, springs, control arms, and alignment procedures.
Brakes:
Front disc and rear drum or disc brakes (depending on trim), including hydraulic system, ABS (if equipped), rotors, pads, calipers, and bleeding procedures.
Steering:
Power rack and pinion steering system, including pump, lines, rack assembly, and alignment.
Electrical:
Complete electrical system diagnosis and repair, including battery, charging system, starting system, lighting, instrumentation, power accessories, and fuses/relays.
HVAC:
Heating, Ventilation, and Air Conditioning systems, including refrigerant, compressor, condenser, evaporator, blower motor, and controls.
Body:
Exterior and interior body panels, doors, windows, latches, hinges, bumpers, and trim component removal/installation.
Restraint Systems:
Airbag system diagnosis and service, seat belt mechanisms.
Procedures Included
Maintenance:
Routine maintenance procedures such as oil changes, filter replacements, tune-ups, and fluid checks.
Troubleshooting:
Diagnostic procedures for common issues, including symptom-based troubleshooting guides and fault code interpretation.
Repair:
Step-by-step repair instructions for virtually all components and systems, from minor adjustments to major overhauls.
Diagnostics:
Detailed diagnostic flowcharts and procedures for identifying the root cause of problems.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Includes detailed wiring diagrams and specifications.
📊 Manual Specifications
File Format
Quality:
High-resolution PDF with searchable text for easy navigation and printing.
Print Quality
Printability:
Designed for printing individual sections or the entire manual, with clear diagrams and legible text.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
ECC (2.0L SOHC 16V I4)
Displacement 1:
1996 cc (121.8 cu in)
Horsepower 1:
132 hp @ 5600 rpm
Torque 1:
130 lb-ft @ 4000 rpm
Engine Code 2:
ECL (2.0L DOHC 16V I4 - High Output)
Displacement 2:
1996 cc (121.8 cu in)
Horsepower 2:
150 hp @ 6000 rpm (standard) / 150 hp @ 6000 rpm (R/T - varies slightly by source)
Torque 2:
135 lb-ft @ 4800 rpm (standard) / 135 lb-ft @ 4800 rpm (R/T)
Performance
Redline Sohc:
6000 RPM
Redline DOHc:
6500 RPM
Fuel System
Injection Type:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 octane recommended, 89+ for optimal performance)
Fuel Tank Capacity:
13.0 gallons (49.2 Liters)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission
Optional
Transmission Type:
4-speed Automatic Transmission (41TE/AE)
Features
Transmission Fluid Spec:
ATF+4 (Mopar)
Manual Clutch Type:
Dry single plate clutch with hydraulic actuation
📐 Dimensions
Exterior
Length:
168.9 inches (4290 mm)
Width:
66.7 inches (1694 mm)
Height:
55.1 inches (1400 mm)
Wheelbase:
104.1 inches (2644 mm)
Front Track:
57.7 inches (1465 mm)
Rear Track:
58.0 inches (1473 mm)
Weights
Curb Weight Min:
2735 lbs (1241 kg)
Curb Weight Max:
2950 lbs (1338 kg)
Gross Vehicle Weight Rating:
3750 lbs (1701 kg)
Cargo
Trunk Volume:
13.0 cu ft (368 Liters)
🛡️ Safety Features
Ratings
NHTSA Driver Front Impact:
4 Stars
NHTSA Passenger Front Impact:
4 Stars
Active Features
ABS:
Available (Standard on R/T, optional on others)
Passive Features
Airbags:
Driver and front passenger airbags
Seatbelts:
Front: three-point, height-adjustable; Rear: three-point, lap belt for center occupant
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM stereo with CD player or cassette player. Optional Infinity premium sound system.
Navigation:
Not available from the factory in 2002.
Driver Assistance
Cruise Control:
Standard on most trims.
Traction Control:
Not commonly equipped.
Connectivity
Bluetooth:
Not available from the factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 miles (4,800 km) or 3 months, whichever comes first (under normal conditions).
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months, or as needed based on conditions.
Spark Plug Replacement:
Every 30,000 miles (48,000 km) for platinum-tipped plugs (standard).
Transmission Fluid Change:
Every 30,000-60,000 miles (48,000-96,000 km), or every 24-48 months, depending on driving conditions.
Fluid Specifications
Engine Oil Spec:
SAE 5W-30 (API Certified)
Coolant Spec:
Mopar Antifreeze/Coolant (Ethylene Glycol based, 50/50 mix with distilled water)
Brake Fluid Spec:
DOT 3
Known Issues
Common Problems 1:
Cooling system leaks (radiator, hoses, water pump).
Common Problems 2:
Power steering pump whine or failure.
Common Problems 3:
Electrical gremlins, particularly with window regulators, door locks, and dashboard components.
Common Problems 4:
Catalytic converter failure (especially on high-mileage vehicles).
Common Problems 5:
Automatic transmission issues (harsh shifting, slipping).
📚 Vehicle History
Brand Heritage
Brand Identity:
Dodge, historically a performance-oriented division of Chrysler, aimed to offer engaging and affordable vehicles.
Model Evolution
Generation:
Second Generation (PL) introduced for the 2000 model year, featuring a redesigned exterior and interior.
Design Philosophy:
The second generation aimed to rectify criticisms of the first generation, with improved refinement, safety, and styling.
Production
Assembly Location:
Belvidere Assembly Plant, Illinois, USA
Production Years:
1995-2005 (Global production, including Chrysler and Mitsubishi variants)
🏆 Awards & Recognition
Recognitions
Award 1:
Consistently ranked as an affordable and fun-to-drive option in its class by automotive reviewers.
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