2002 Dodge Neon Service and Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Neon Year: 2002 Codes Platform: Chrysler PL platform (second generation) 👋 Introduction Market Position Segment: Compact car, known for affordability and fuel efficiency....

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Type: Car

Vendor:

Sku: 456168

Tags: 2002 Car Cars Dodge Misc Neon

Product variants

Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Year:

Codes

Platform:

Chrysler PL platform (second generation)

👋 Introduction

Market Position

Segment:

Compact car, known for affordability and fuel efficiency.

Competitive Analysis

Competitors:

Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier.

Key Features

Distinctive Selling Points:

Sporty styling (for its class), available performance variants (e.g., ACR), competitive pricing.

Manual Usefulness

Target Audience:

Professional automotive technicians, dealership service departments, and experienced DIY enthusiasts.

Manual Value

Value Proposition:

Provides dealership-level diagnostic and repair information, ensuring accuracy and completeness for all service needs.

📋 Manual Details

Coverage Areas

Coverage Scope:

All models and all repairs A-Z

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Print (assumed based on typical product offering for this type of manual)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, engine performance, fuel system, exhaust system, ignition system, cooling system, lubrication system, starting and charging system.

Transmission:

Manual transmission (Getrag MS-300), Automatic transmission (Chrysler 41TE/42LE).

Chassis:

Braking system (front disc, rear drum/disc depending on model), steering system (power rack and pinion), suspension system (front MacPherson strut, rear twist beam axle with trailing arms), wheels and tires.

Electrical:

Body electrical systems, lighting, instrumentation, audio systems, power accessories (windows, locks, mirrors), anti-theft system, airbag system (SRS).

Body:

Body construction, exterior trim, interior trim, doors, glass, bumpers, body panel repairs.

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, brake inspections, tire rotations.

Diagnostics:

Troubleshooting charts, diagnostic trouble codes (DTCs), symptom-based diagnostics, electrical system diagnosis.

Repair:

Component removal and installation, disassembly and reassembly, component testing and adjustment, calibration procedures.

Technical Data:

Torque specifications, fastener tightening sequences, wiring diagrams, vacuum diagrams, component specifications.

Technical Depth

Depth:

Complete diagnostic and repair procedures, suitable for professional technicians and advanced DIYers.

📊 Manual Specifications

File Format

Format Type:

Print Quality

Quality:

High-quality paper stock, clear and legible diagrams, professional printing.

Binding Type

Binding:

Sturdy binding, likely perfect binding or spiral bound for ease of use in a workshop environment.

Paper Type

Paper:

Durable, matte finish paper to reduce glare in workshop lighting.

⚙️ Engine Specifications

Primary Engine

Engine Code:

Configuration:

Inline 4-cylinder

Displacement:

2.0 Liters (1996 cc)

Valvetrain:

SOHC (Single Overhead Camshaft) 16-valve

Performance

Horsepower:

Approx. 132 hp @ 6000 RPM (varies slightly by trim/model)

Torque:

Approx. 130 lb-ft @ 4500 RPM (varies slightly by trim/model)

Fuel System

Induction:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline

Engine Management

Proprietary Chrysler Powertrain Control Module (PCM)

Cooling System

Coolant Type:

HOAT (Hybrid Organic Acid Technology) G-05 coolant, typically Mopar brand or equivalent (e.g., Zerex G-05).

Lubrication System

Oil Type:

SAE 5W-30 Synthetic Blend or Full Synthetic.

Oil Capacity:

Approx. 4.5 quarts (4.3 liters) with filter.

Engine Variants

Performance Variant:

SRT-4 engine (2.4L Turbocharged I4, ~200 hp) not covered in standard 2.0L manual, but may be a separate manual if applicable to the model year.

🔧 Transmission

Standard

Type:

Getrag MS-300 5-speed Manual Transmission

Optional

Type:

Chrysler 41TE / 42LE 4-speed Automatic Transmission

Features

Automatic Control:

Electronically controlled with overdrive.

Manual Fluid

Fluid Type:

API GL-4 SAE 75W-90 Synthetic Gear Oil.

Automatic Fluid

Fluid Type:

ATF+4 (Chrysler's proprietary automatic transmission fluid, may specify a compatible ATF type like Mopar or Castrol ATF+4).

Fluid Capacity:

Approx. 7.6 quarts (7.2 liters) for fill, higher for complete overhaul.

📐 Dimensions

Exterior

Wheelbase:

Approx. 104.1 inches (2644 mm)

Length:

Approx. 174.4 inches (4430 mm)

Width:

Approx. 67.4 inches (1712 mm)

Height:

Approx. 54.1 inches (1374 mm)

Weights

Curb Weight:

Approx. 2700-2900 lbs (1225-1315 kg) depending on configuration.

Gross Vehicle Weight Rating:

Typically around 3700 lbs (1678 kg).

Cargo

Trunk Capacity:

Approx. 13.1 cubic feet (371 liters)

Wheels And Tires

Standard Tire Size:

185/70R14 or 195/60R15, depending on trim.

Wheel Bolt Pattern:

4x100mm

Wheel Offset:

ET40-42 typical

🛡️ Safety Features

Ratings

NHTSA Frontal Crash:

Driver: 4 Stars, Passenger: 4 Stars (NHTSA ratings for 2002 models).

NHTSA Side Impact:

Front Driver: 4 Stars, Front Passenger: 5 Stars, Rear Driver: 4 Stars, Rear Passenger: 4 Stars (NHTSA ratings for 2002 models).

Active Features

Available on most trims, typically front disc, rear drum (optional rear disc).

Traction Control:

Not commonly available on standard models for 2002.

Passive Features

Airbags:

Standard dual front airbags (driver and passenger), optional side airbags.

Seatbelts:

Three-point front and rear seatbelts, driver and front passenger pretensioners.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional cassette or premium audio.

Display:

Basic digital clock and radio display. No touchscreen or advanced navigation.

Driver Assistance

Cruise Control:

Available on most trims.

Keyless Entry:

Available as an option on some trims.

Connectivity

Auxiliary Input:

Not standard. May require aftermarket modification.

Comfort Features

Air Conditioning:

Standard on most trims.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first, using synthetic oil. For conventional oil, typically 3,000-5,000 miles.

Air Filter Replacement:

Every 30,000 miles (48,000 km) or as needed based on driving conditions.

Spark Plug Replacement:

Typically every 60,000 miles (96,000 km) for platinum-tipped plugs.

Timing Belt Replacement:

This engine uses a timing chain, not a belt, which is generally maintenance-free for the life of the engine, but inspection is recommended at higher mileage.

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

Chrysler power steering fluid (Type MS-5951) or equivalent.

Known Issues

Engine:

Head gasket failures can occur, especially if overheated. Some reports of oil pump issues. PCV valve can become clogged.

Transmission:

Automatic transmission can develop internal seal leaks or solenoid failures. Manual transmission clutch wear is typical.

Suspension And Steering:

Worn ball joints, tie rod ends, and sway bar links are common. Power steering pump can leak or fail.

Electrical:

Window regulator motors, power lock actuators, and instrument cluster failures are reported.

📚 Vehicle History

Brand Heritage

Manufacturer:

Dodge, a division of Chrysler Corporation (later DaimlerChrysler).

Model Evolution

Generation:

Second Generation (2000-2006), significant redesign from the first generation, featuring a more modern exterior and interior, and improved chassis dynamics.

Production

Manufacturing Location:

Sterling Heights, Michigan, USA.

Production Period:

Second generation production ran from model year 2000 to 2006.

🏆 Awards & Recognition

Recognitions

Category:

Automotive journalism awards for affordability and value.

Example Award:

While specific awards for the 2002 model are not as prominent as later years or other brands, the Neon was generally recognized for offering good value in the subcompact segment.

Ratings

Insurance Institute Highway Safety:

Ratings vary, but second-generation Neons generally received 'Acceptable' or 'Good' ratings in frontal and side impact tests, depending on specific equipment and testing protocols.