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Dodge SX 2.0 2003 2004 2005 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: SX 2.0 Year: 2003-2005 Codes Platform Code: PM (Project 'Mitsubishi Explorer') 👋 Introduction Market Position Vehicle Segment: Compact/Subcompact Crossover SUV Target Audience: Budget-conscious...
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Dodge SX 2.0 2003 2004 2005 Workshop Service Repair ManualDodge SX 2.0 2003 2004 2005 Workshop Service Repair ManualDodge SX 2.0 2003 2004 2005 Workshop Service Repair ManualDodge SX 2.0 2003 2004 2005 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
SX 2.0
Year:
2003-2005
Codes
Platform Code:
PM (Project 'Mitsubishi Explorer')
👋 Introduction
Market Position
Vehicle Segment:
Compact/Subcompact Crossover SUV
Target Audience:
Budget-conscious consumers seeking versatile compact utility
Competitive Analysis
Key Competitors:
Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute
Key Features
Vehicle Design Origin:
Based on Mitsubishi platform (shared with Mitsubishi Outlander)
Value Proposition:
Affordability, practicality, and a higher seating position compared to sedans
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive workshop service and repair
Page Count
Estimated Page Count:
Over 1500 pages (typical for this era of comprehensive manuals)
Manual Type
Manual Format Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Digital Format:
PDF (Searchable, Printable)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, emission controls, engine management (ECM/PCM)
Transmission Systems:
Manual Transmission (MT) and Automatic Transmission (AT) diagnostics, repair, and overhaul
Drivetrain Systems:
Front Wheel Drive (FWD) system, CV joints, drive shafts
Suspension Systems:
Front and rear suspension, steering system, alignment specifications
Brake Systems:
Front and rear brakes (disc/drum), ABS, brake fluid specifications, bleeding procedures
Electrical Systems:
Battery, charging system, starting system, lighting, instrumentation, power accessories, body control module (BCM), fuse box diagrams, wiring diagrams
HVAC Systems:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair
Body Interior Systems:
Body panels, doors, windows, interior trim, seats, airbags
Safety Systems:
Airbag system, seat belts, ABS
Procedures Included
General Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement
Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, wiring diagram interpretation
Repair Procedures:
Step-by-step instructions for component removal, installation, and overhaul
Diagnostic Procedures:
Use of diagnostic scan tools, live data interpretation, actuator testing
Specification Data:
Torque specifications, clearances, fluid capacities, electrical specifications
Technical Depth
Depth Of Coverage:
Comprehensive (from basic maintenance to complete engine/transmission rebuilds)
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable for quick information retrieval
Print Quality
Printability:
High-resolution, printable pages
Binding Type
Digital Binding:
N/A (Digital format)
Paper Type
Digital Paper Simulation:
Simulated (for printout purposes)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G64 (Mitsubishi Astron family)
Engine Type:
Inline 4-Cylinder, DOHC, 16-valve
Displacement:
2.4 Liters (2351 cc)
Performance
Horsepower:
Approx. 145-150 hp @ 5500-6000 RPM (depending on year/spec)
Torque:
Approx. 160-165 lb-ft @ 3500-4000 RPM (depending on year/spec)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Engine Management
ECU Type:
Mitsubishi-based Engine Control Unit (ECU)
Emission Controls
Emission System:
Catalytic converter, oxygen sensors, EGR (likely)
🔧 Transmission
Standard
Transmission Type Standard:
4-speed Automatic Transmission (4F20E or similar)
Optional
Transmission Type Optional:
5-speed Manual Transmission
Features
Drive Configuration:
Front-Wheel Drive (FWD) standard, All-Wheel Drive (AWD) optional
Fluid Specifications
Automatic Transmission Fluid Type:
Chrysler ATF+4 (or equivalent Mopar specification)
Manual Transmission Fluid Type:
GL-3 or GL-4 gear oil (refer to manual for specific viscosity)
📐 Dimensions
Exterior
Length:
Approx. 169.3 inches (4300 mm)
Width:
Approx. 69.7 inches (1770 mm)
Height:
Approx. 65.2 inches (1656 mm)
Wheelbase:
Approx. 103.0 inches (2616 mm)
Weights
Curb Weight:
Approx. 3200-3400 lbs (1450-1540 kg)
Cargo
Cargo Volume Behind Rear Seat:
Approx. 25.1 cubic feet (710 liters)
Cargo Volume With Rear Seat Folded:
Approx. 68.9 cubic feet (1950 liters)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
Likely 4 stars (based on similar vehicles of the era)
NHTSA Frontal Impact Passenger:
Likely 4 stars (based on similar vehicles of the era)
IIHS Frontal Offset:
Likely Acceptable or Marginal (based on platform sharing)
Active Features
ABS:
Standard on most trims
Passive Features
Airbags:
Front driver and passenger airbags
Seat Belts:
3-point front and rear seat belts
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for CHildren) system
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional cassette and premium sound system
Display:
Basic digital display for radio and clock
Driver Assistance
Cruise Control:
Standard on most models
Connectivity
Auxiliary Input:
Not typically available on factory systems of this era
Power Outlets:
12V auxiliary power outlets
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months (refer to manual for exact recommendation)
Engine Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on inspection
Cabin Air Filter Replacement:
Every 12,000-15,000 miles or annually
Spark Plug Replacement:
Every 60,000-100,000 miles (depending on plug type, e.g., iridium)
Transmission Fluid Change:
Every 30,000-60,000 miles (depending on usage and fluid type)
Fluid Specifications
Engine Oil Type:
SAE 5W-30 or 5W-40 (API SM/SN or equivalent)
Engine Oil Capacity:
Approx. 4.5 quarts (4.2 Liters) with filter
Coolant Type:
IAT (Inorganic Additive Technology) green coolant or HOAT (Hybrid Organic Additive Technology) compatible (refer to manual)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Engine Idling Roughness:
Can be caused by dirty throttle body, vacuum leaks, or failing O2 sensors
Transmission Slipping Or Harsh Shifting:
Often related to low fluid level, worn clutch packs, or solenoid issues
Check Engine Light Illumination:
Common causes include faulty O2 sensors, catalytic converter issues, or EVAP system leaks
Suspension Noises:
Worn ball joints, tie rod ends, or sway bar links can produce clunking or rattling sounds
Cooling System Leaks:
Radiator, hoses, or water pump leaks are common wear items
📚 Vehicle History
Brand Heritage
Dodge Brand Focus:
Historically known for performance and value
Model Evolution
Dodge Sx 2.0 Origin:
Rebadged Mitsubishi Outlander, part of DaimlerChrysler's global platform strategy
Dodge Sx 2.0 Market Entry:
Introduced for the 2003 model year
Production
Manufacturing Location:
Japan (as Mitsubishi Outlander), reassembled/modified for Dodge market
🏆 Awards & Recognition
Recognitions
Specific Awards:
No prominent major awards specifically for the Dodge SX 2.0, but its platform cousin (Mitsubishi Outlander) may have received some industry recognition for its practicality.
Ratings
Consumer Reports Reliability:
Generally considered average to below-average for the period, especially concerning transmission and electrical systems.
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