Dodge Neon 2003 2004 2005 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Dodge Model: Neon Years Covered: 2003, 2004, 2005 Codes Platform: Chrysler JA Platform (Second Generation Neon) 👋 Introduction Market Position Segment: Compact Car Competitive Analysis...

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Type: Car

Vendor:

Sku: 428867

Tags: 2003 2004 2005 Car Cars Dodge Misc Neon

Product variants

Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Years Covered:

2003, 2004, 2005

Codes

Platform:

Chrysler JA Platform (Second Generation Neon)

👋 Introduction

Market Position

Segment:

Compact Car

Competitive Analysis

Competitors:

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

Key Features

Styling:

Distinctive, often polarizing, 'cab-forward' design with rounded styling cues.

Performance Variants:

Available in base models and performance-oriented 'SRT-4' variants (though SRT-4 is typically focused on 2003-2005 for the later generation, this manual covers the entire generation range).

Value Proposition:

Offered competitive pricing and a range of features for its segment.

📋 Manual Details

Coverage Areas

Coverage Type:

Workshop Service Manual

Page Count

Estimated Pages:

Over 2000 pages (typical for comprehensive workshop manuals)

Manual Type

Type:

Service Manual / Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, repair procedures, specifications for 2.0L SOHC and DOHC engines (Chrysler Neon engine family).

Transmission:

Repair and overhaul for automatic (41TE/42LE) and manual (Getrag NV1500/NV3500) transmissions.

Brakes:

Front and rear brake system diagnostics, component replacement (pads, rotors, calipers, lines), ABS system troubleshooting.

Suspension Steering:

Front and rear suspension component repair (struts, shocks, control arms, ball joints, bushings), steering system diagnostics and repair (rack and pinion, power steering).

Electrical:

Comprehensive wiring diagrams, component testing, diagnostic procedures for lighting, ignition, charging, starting, body control modules, power windows/locks, HVAC controls.

Body:

Body panel alignment, door hardware, interior trim, glass replacement, collision repair guidelines.

HVAC:

Air conditioning system service, refrigerant handling, heater core replacement, blower motor diagnostics.

Fuel:

Fuel pump, injectors, filter replacement, fuel system pressure testing, evaporative emissions control (EVAP).

Exhaust:

Exhaust system component replacement, catalytic converter information, muffler service.

Cooling:

Radiator, water pump, thermostat, coolant specifications and replacement procedures, cooling fan diagnostics.

Emissions:

On-Board Diagnostics (OBD-II) troubleshooting, emission control system components and function.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement.

Diagnostics Troubleshooting:

Step-by-step diagnostic flowcharts for common and complex issues, error code interpretation.

Component Replacement:

Detailed instructions for replacing major and minor components across all vehicle systems.

Engine Rebuild:

Full engine disassembly, inspection, repair, and reassembly procedures, including torque specifications.

Transmission Overhaul:

Complete teardown, inspection, and rebuilding of automatic and manual transmissions.

Electrical Repairs:

Component testing, wiring harness repair, module programming/diagnostics (where applicable).

Body Work:

Panel repair, door and window adjustments, interior trim removal and installation.

Special Tools:

Identification and usage of specialized tools required for specific repair procedures.

Technical Depth

Depth:

Comprehensive, suitable for professional technicians and advanced DIYers. Covers from basic maintenance to full engine and transmission rebuilds.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Print Quality

Quality:

High resolution, clear diagrams and text. Searchable text for easy navigation.

Binding Type

Binding:

Not Applicable (Digital PDF)

Paper Type

Paper Quality:

Not Applicable (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code:

ECC/EDZ (2.0L SOHC MPI)

Displacement:

1995 cc (2.0 Liters)

Configuration:

Inline 4-cylinder

Engine Code DOHc:

ECL (2.0L DOHC MPI)

Performance

Horsepower Sohc:

132 hp @ 5800 rpm

Torque Sohc:

130 lb-ft @ 3250 rpm

Horsepower DOHc:

145 hp @ 6000 rpm (standard DOHC)

Torque DOHc:

135 lb-ft @ 4800 rpm (standard DOHC)

Horsepower Srt4:

200 hp @ 5600 rpm (for SRT-4 variant)

Torque Srt4:

220 lb-ft @ 3000 rpm (for SRT-4 variant)

Fuel System

Type:

Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane recommended, higher for performance models)

Engine Management

Chrysler Powertrain Control Module (PCM), specific programming for engine/transmission configuration.

🔧 Transmission

Standard

Type:

5-Speed Manual Transmission (e.g., Getrag NV1500/NV3500)

Optional

Type:

4-Speed Automatic Transmission (e.g., Chrysler 41TE/42LE)

Features

Automatic Mode:

Adaptive electronic control with torque converter lock-up.

Manual Clutch:

Hydraulic actuation for manual transmissions.

Fluid Specifications

Automatic Fluid Type:

ATF+4 (MS-9602) or equivalent

Manual Fluid Type:

MS-9070 (or specific manual transmission fluid)

📐 Dimensions

Exterior

Length:

Approx. 174.4 inches (4430 mm)

Width:

Approx. 67.7 inches (1720 mm)

Height:

Approx. 54.9 inches (1395 mm)

Wheelbase:

Approx. 104.1 inches (2644 mm)

Weights

Curb Weight:

Approx. 2700-2900 lbs (1225-1315 kg), varies by trim and equipment.

Gross Vehicle Weight Rating:

Varies by model, typically around 3700 lbs.

Cargo

Trunk Volume:

Approx. 13.0 cubic feet (sedan)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

Good (for 2003 model year, specific ratings vary by year and testing methodology)

NHTSA Frontal Impact Passenger:

Good (for 2003 model year)

IIHS Moderate Overlap Frontal Offset:

Acceptable (for models tested in this range)

Active Features

Standard on most trims, optional on some base models.

Traction Control:

Optional on select models.

Passive Features

Airbags Front:

Standard driver and front passenger airbags.

Airbags Side:

Optional side-impact airbags on some trims.

Seatbelts:

Three-point front and rear seat belts, pretensioners on front seats.

💡 Technology Features

Infotainment

Audio System:

Optional AM/FM stereo with CD player, premium Infinity sound system available on higher trims.

Display:

Basic analog gauges, central display for odometer and trip computer.

Driver Assistance

Cruise Control:

Available on most models.

Connectivity

Aux Input:

Not standard, aftermarket solutions often available.

Comfort Features

Power Options:

Power windows, power locks, power mirrors available on higher trims.

🔧 Maintenance

Service Intervals

Oil Change:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first (under normal driving conditions).

Air Filter Replacement:

Every 30,000 miles (48,000 km).

Spark Plug Replacement:

Every 100,000 miles (160,000 km) for platinum-tipped plugs.

Coolant Flush:

Every 100,000 miles (160,000 km) or 5 years.

Fluid Specifications

Engine Oil:

SAE 5W-30 Synthetic Blend or Full Synthetic (API SN or later).

Coolant:

Chrysler OAT (Organic Additive Technology) antifreeze/coolant, color Orange. Or equivalent HOAT (Hybrid OAT).

Brake Fluid:

DOT 3 or DOT 4.

Known Issues

Engine:

Head gasket leaks, oil leaks, intake manifold gasket leaks, some oil consumption issues.

Transmission:

Automatic transmission solenoid failures, hard shifting, manual transmission clutch wear.

Suspension Steering:

Worn control arm bushings, ball joints, tie rod ends, power steering pump leaks.

Electrical:

Window regulator failures, power lock actuator issues, instrument cluster problems, O2 sensor failures.

HVAC:

Blend door actuator failures, AC compressor issues, heater core leaks.

📚 Vehicle History

Brand Heritage

Manufacturer:

Dodge (a division of Chrysler Corporation, later Chrysler Group LLC)

Model Evolution

Generation:

Second Generation Neon (PL platform, though often referred to as JA for this specific generation's development timeline).

Design Changes:

Updated styling, improved interior quality, more refined suspension compared to the first generation.

Production

Production Years:

2000-2005 (for the second generation, this manual specifically covers 2003-2005).

Assembly Locations:

Belvidere, Illinois, USA.

🏆 Awards & Recognition

Recognitions

Safety Award:

Achieved Good ratings in NHTSA frontal impact tests for some model years.

Ratings

Consumer Satisfaction:

Varied depending on the specific model year and reviewer, often cited for its value but sometimes criticized for reliability compared to segment leaders.