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Dodge Neon SRT-4 2004 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Dodge Model: Neon SRT-4 Year: 2004 Codes Chassis Code: PT Engine Code: ECL (2.4L Turbocharged DOHC) 👋 Introduction Market Position Segment: Compact performance sedan, targeting...
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Dodge Neon SRT-4 2004 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Neon SRT-4
Year:
2004
Codes
Chassis Code:
PT
Engine Code:
ECL (2.4L Turbocharged DOHC)
👋 Introduction
Market Position
Segment:
Compact performance sedan, targeting enthusiasts seeking accessible power and sporty driving dynamics.
Competitive Analysis
Competitors:
Subaru WRX, Mitsubishi Lancer Evolution (though often positioned slightly above), Honda Civic Si, Volkswagen GTI.
Key Features
Performance Focus:
Emphasizes turbocharged engine power, sport-tuned suspension, and aggressive styling.
Value Proposition:
Offers a compelling performance package at a more affordable price point than many direct competitors.
📋 Manual Details
Coverage Areas
Coverage:
All Models, Engines, Trims, and Transmissions
Page Count
Pages:
Extensive (Specific count not provided, but implied to be comprehensive)
Manual Type
Type:
Workshop Repair and Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
2.4L Turbocharged DOHC (ECL), including turbocharger system, fuel injection, ignition, cooling, lubrication, and emission control.
Transmission:
Manual Transmission (Getrag NVT-4500), including clutch system, gearshift linkage, and internal components.
Drivetrain:
Front-wheel drive system, including drive axles, CV joints, and differential.
Suspension:
Front and rear suspension systems, including MacPherson struts, coil springs, shock absorbers, control arms, and anti-roll bars.
Brakes:
Front and rear disc brakes, ABS system, parking brake, hydraulic lines, and components.
Steering:
Power-assisted rack and pinion steering system.
Electrical:
12V electrical system, battery, alternator, starter, lighting, ignition switch, fuses, relays, and wiring diagrams.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, including refrigerant, compressor, evaporator, and controls.
Body And Frame:
Body panel removal and installation, interior trim, glass, doors, hood, trunk, and chassis components.
Interior:
Seats, dashboard, instrument panel, airbags, seatbelts, and interior trim components.
Diagnostics:
OBD-II diagnostic trouble codes (DTCs), diagnostic procedures, and troubleshooting flowcharts.
Procedures Included
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, spark plug replacement, fluid checks, and belt inspections.
Repair:
Component removal, installation, overhaul, and repair procedures for all major vehicle systems.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving mechanical and electrical issues.
Disassembly Assembly:
Detailed steps for disassembling and reassembling engine, transmission, suspension, and other major components.
Torque Specifications:
Precise torque values for all fasteners and critical components.
Wiring Diagrams:
Comprehensive electrical wiring schematics for all vehicle systems.
Technical Depth
Depth:
Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical troubleshooting.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Print Quality
Quality:
High-resolution, suitable for digital viewing and printing.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
Searchability
Text Search:
Searchable text content for quick information retrieval.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, turbocharged, intercooled, DOHC (Dual Overhead Camshafts)
Displacement:
2378 cc (2.4 Liters)
Bore X Stroke:
87.5 mm x 98.0 mm
Compression Ratio:
8.1:1
Engine Code:
ECL
Performance
Horsepower Hp:
230 hp @ 5800 rpm
Torque Lb-Ft:
250 lb-ft @ 3600 rpm (with Overboost function potentially providing more)
Redline:
6500 rpm (approx.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Sequential Port Injection, Turbocharged
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Turbocharger Model:
Garrett GT2554R (or similar)
Intercooler:
Front-mounted air-to-air intercooler
🔧 Transmission
Standard
Type:
5-Speed Manual Transmission (Getrag NVH-3500 / NVT-4500)
Gear Ratios:
1st: 3.143, 2nd: 1.944, 3rd: 1.379, 4th: 1.032, 5th: 0.775, Reverse: 2.917 (Typical Getrag ratios for this application)
Final Drive Ratio:
3.438:1
Clutch Type:
Hydraulically actuated, single dry plate
Optional
Type:
None (SRT-4 was exclusively manual)
Features
Limited Slip Differential:
Optional on some models, standard on later production runs or specific packages.
📐 Dimensions
Exterior
Length:
174.4 inches (4430 mm)
Width:
67.7 inches (1720 mm)
Height:
55.5 inches (1410 mm)
Wheelbase:
105.1 inches (2670 mm)
Front Track:
58.4 inches (1483 mm)
Rear Track:
58.2 inches (1478 mm)
Weights
Curb Weight:
Approx. 2999 lbs (1360 kg)
Gross Vehicle Weight Rating:
Approx. 3770 lbs (1710 kg)
Payload Capacity:
Approx. 771 lbs (349 kg)
Cargo
Trunk Volume:
12.4 cu ft (351 L)
🛡️ Safety Features
Ratings
NHTSA Driver Front Impact:
Good (for 2004 models)
NHTSA Passenger Front Impact:
Good (for 2004 models)
IIHS Moderate Overlap Frontal Offset:
Good (for 2004 models)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS) on some models.
Brake Bias:
Performance-oriented brake setup, often with larger front rotors and calipers compared to standard Neon models.
Passive Features
Airbags Front:
Driver and front passenger airbags.
Airbags Side:
Optional side-impact airbags available.
Seatbelts:
3-point front and rear seatbelts with pretensioners.
Rollover Protection:
Reinforced body structure with enhanced pillar strength.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, often with premium speaker options and steering wheel audio controls on higher trims.
Display:
Basic digital clock and radio display. No advanced infotainment screens standard.
Driver Assistance
Cruise Control:
Standard cruise control.
Keyless Entry:
Available keyless entry system.
Connectivity
Phone Integration:
No integrated Bluetooth or smartphone connectivity from the factory. Aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000-5,000 miles or 3-6 months, depending on driving conditions. Refer to manual for specific severe vs. normal service.
Air Filter:
Inspect every 15,000 miles, replace as needed (typically every 30,000 miles).
Spark Plugs:
Replace every 30,000-45,000 miles (specific spark plug type and gap are critical).
Coolant Flush:
Every 30,000 miles or 3 years.
Transmission Fluid:
Inspect every 15,000 miles, replace as needed. Manual transmission fluid change typically every 60,000 miles.
Timing Belt:
Non-interference engine, but inspection and potential replacement recommended around 100,000 miles for accessory belts and tensioners.
Fluid Specifications
Engine Oil:
SAE 0W-30 Synthetic or SAE 5W-30 Synthetic (Chrysler MS-6395 approved). Consult manual for exact viscosity and API service classification.
Coolant:
Mopar OAT (Organic Additive Technology) Antifreeze/Coolant or equivalent (HOAT acceptable).
Brake Fluid:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Power Steering Fluid:
Mopar Power Steering Fluid or Dexron III/Mercon ATF.
Transmission Fluid:
GL-4 Synthetic Gear Oil (specific viscosity to be confirmed in manual, typically 75W-90).
Known Issues
Clutch Wear:
Can be subject to premature wear under aggressive driving or abuse.
Turbocharger Failure:
Turbo seals and bearings can fail if oil maintenance is neglected or due to extreme heat cycles.
Motor Mounts:
Hydraulic motor mounts can degrade and leak over time, causing vibration.
Fuel Injectors:
Can become clogged, affecting performance. Regular use of quality fuel and occasional injector cleaner is recommended.
Engine Oil Leaks:
Leaky valve cover gaskets or oil pan gaskets are common as the vehicle ages.
Suspension Components:
Sway bar links, ball joints, and tie rod ends can wear out due to the performance-oriented suspension setup.
📚 Vehicle History
Brand Heritage
Manufacturer:
Dodge (a division of Chrysler Corporation, later Chrysler Group LLC, now Stellantis).
Model Evolution
Neon Generations:
The Neon was first introduced in 1994 (first generation, PT). The 2004 SRT-4 is part of the second generation (2000-2005, PL). SRT-4 variant introduced for 2003 model year.
Srt Development:
Developed by Chrysler's Street & Racing Technology (SRT) division, transforming the standard Neon into a high-performance compact.
Production
Manufacturing Plant:
Belvidere Assembly Plant, Illinois, USA.
Production Years Srt4:
2003-2005.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The Dodge Neon SRT-4 was frequently lauded by automotive publications for its performance value, though it didn't specifically make Car and Driver's 10Best list in 2004, it was a strong contender in its segment.
Specialty Equipment Market Association Sema:
SRT-4 models were popular platforms for SEMA show builds, highlighting their performance potential.
Ratings
Performance Value:
Consistently rated highly for its performance-per-dollar ratio.
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