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2002 Dodge Neon Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Neon Year: 2002 Generation Generation Identifier: Second Generation (PL) Codes Platform Code: PL 👋 Introduction Market Position Segment: Compact Car Target Audience: DIY...
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2002 Dodge Neon Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Neon
Year:
2002
Generation
Generation Identifier:
Second Generation (PL)
Codes
Platform Code:
PL
👋 Introduction
Market Position
Segment:
Compact Car
Target Audience:
DIY mechanics, independent repair shops, Dodge Neon owners seeking in-depth repair information.
Competitive Analysis
Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier
Key Features
Value Proposition:
Provides factory-level diagnostic and repair procedures, essential for accurate and efficient servicing of the 2002 Dodge Neon. Crucial for maintaining vehicle integrity and performance.
📋 Manual Details
Coverage Areas
Primary Coverage:
2002 Dodge Neon
Secondary Coverage:
All trim levels and engine variants for the 2002 model year
Page Count
Estimated Page Count:
1500-2000+
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital Download (WinRAR Archive containing PDF files)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (including specific variants), Transaxle (manual and automatic), Clutch, Driveline, Fuel System, Exhaust System, Emissions Control
Chassis:
Suspension (front and rear), Steering, Brakes (hydraulic, ABS), Wheels, Tires
Electrical And Electronics:
Wiring Diagrams, Electronic Control Modules (ECM/PCM), Ignition Control, Audio System, Chime/Buzzer, Horn, Instrument Cluster, Lamps, Message Systems, Power Systems (windows, locks, mirrors), Speed Control, Vehicle Theft Security, Wipers/Washers
Body And Interior:
Body (structure, panels), Frame & Bumpers, Heating & Air Conditioning (HVAC)
Chassis Components:
Detailed procedures for front and rear suspension component replacement (struts, shocks, control arms, ball joints, tie rod ends), steering rack and pinion service, brake caliper, rotor, and pad replacement, parking brake adjustments.
Heating And Air Conditioning:
Refrigerant type and capacity (R-134a), compressor service, blower motor replacement, HVAC control head diagnostics, heater core and evaporator core replacement procedures.
Procedures Included
Maintenance:
Scheduled maintenance, fluid level checks and changes, lubrication, filter replacements
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), electrical circuit testing, component testing
Repair:
Component removal and installation, adjustments, system overhauls, rebuild procedures for major assemblies
Technical Specifications:
Torque specifications, clearances, alignment data, diagnostic parameters
Engine Rebuild:
Complete engine disassembly, inspection, machining specifications, assembly procedures, timing belt replacement (if applicable, or chain), piston ring and bearing replacement.
Transmission Overhaul:
Detailed steps for disassembling, inspecting, and reassembling both manual and automatic transmissions, including torque converter replacement, clutch pack replacement, and valve body servicing.
Body And Trim:
Procedures for door panel removal, interior trim panel replacement, bumper cover removal and installation, headlight and taillight assembly replacement.
Technical Depth
Depth:
Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds, including detailed electrical schematics and troubleshooting pathways.
Wiring Diagrams:
Extensive and detailed wiring schematics for all electrical systems, including power distribution, lighting, engine controls, body electronics, and chassis control modules. Essential for complex electrical troubleshooting.
📊 Manual Specifications
File Format
Primary Format:
PDF
Compression Format:
WinRAR
Print Quality
Digital Quality:
High-resolution, printable pages with clear diagrams and text.
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper Type:
Not Applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code And Description:
2.0L SOHC (Single Overhead Cam) I4 (4-cylinder) - Engine Code: ATEC
Engine Code And Description Performance:
2.0L DOHC (Double Overhead Cam) I4 - Engine Code: GT (SRT-4 variant)
Performance
Horsepower Sohc:
132 hp @ 6000 rpm
Torque Sohc:
130 lb-ft @ 4500 rpm
Horsepower DOHc:
150 hp @ 6400 rpm (standard DOHC)
Torque DOHc:
135 lb-ft @ 4800 rpm (standard DOHC)
Horsepower Srt-4:
200 hp @ 5800 rpm (SRT-4 variant)
Torque Srt-4:
200 lb-ft @ 2200 rpm (SRT-4 variant)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 octane recommended for standard engines, premium may be required for SRT-4)
Engine Construction
Block Material:
Aluminum Alloy
Cylinder Head Material:
Aluminum Alloy
🔧 Transmission
Standard
Type:
5-Speed Manual Transaxle
Optional
Type:
4-Speed Automatic Transaxle
Features
FWD Layout:
Front-Wheel Drive (FWD)
Fluid Specifications
Manual Transmission Fluid:
Chrysler MS-90314 (or equivalent API GL-4 SAE 75W-90 synthetic gear oil)
Automatic Transmission Fluid:
ATF+4 (Chrysler MS-9602)
📐 Dimensions
Exterior
Length:
169.1 inches (4300 mm)
Width:
67.4 inches (1712 mm)
Height:
55.1 inches (1400 mm)
Wheelbase:
104.4 inches (2652 mm)
Weights
Curb Weight:
Approximately 2600-2900 lbs (1179-1315 kg) depending on configuration
Gross Vehicle Weight Rating:
Varies by model, typically around 3600-3800 lbs
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
Four-star driver, Four-star passenger (for 2002 model year)
IIHS Frontal Offset:
Acceptable (for models equipped with optional side airbags)
Active Features
ABS:
Standard on most trims, optional on some base models.
Passive Features
Airbags:
Standard front airbags. Optional side airbags available on some trims.
Seatbelts:
Three-point front and rear seat belts with pretensioners.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with optional cassette. Basic speaker configurations.
Display:
Digital or analog display for radio and climate controls, LCD segments for instrument cluster.
Driver Assistance
Cruise Control:
Available as an option on many trims.
Connectivity
Power Accessories:
Power windows, power door locks, power mirrors were available options on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6 months, whichever comes first (check manual for specific oil type and conditions).
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed.
Spark Plug Replacement:
Every 60,000 - 100,000 miles (96,000 - 160,000 km) depending on spark plug type (standard vs. platinum/iridium).
Fluid Specifications
Engine Oil Capacity:
4.5 quarts (4.3 liters) with filter (for 2.0L engines)
Engine Oil Type:
SAE 5W-30 API Service SG or higher (check manual for specific viscosity and certification)
Coolant Type:
Chrysler 5-Year/100,000 Mile Formula (Ethylene Glycol based, OAT - Organic Additive Technology)
Brake Fluid Type:
DOT 3
Power Steering Fluid:
ATF+4 or specific Mopar power steering fluid.
Known Issues
Engine:
Oil sludge buildup in SOHC engines if maintenance is neglected, occasional head gasket failures, intake manifold gasket leaks.
Transmission:
Automatic transmission solenoid issues, manual clutch wear.
Suspension:
Front strut mount bearing failure, worn control arm bushings, rear axle bearings.
Electrical:
Faulty power window regulators, intermittent instrument cluster issues, HVAC blower motor resistor failure.
📚 Vehicle History
Brand Heritage
Parent Company:
Chrysler Corporation (later DaimlerChrysler, then Fiat Chrysler Automobiles)
Model Evolution
Generation Introduction:
The second generation Dodge Neon (PL platform) was introduced for the 2000 model year, with significant updates for 2002 including styling revisions and the introduction of the high-performance SRT-4 variant.
Production
Manufacturing Location:
Belvidere, Illinois, USA
Production Years For Generation:
2000-2005
🏆 Awards & Recognition
Recognitions
Automotive Press:
The Dodge Neon, particularly the second generation, was generally well-received for its sporty handling and affordable pricing, although reliability was sometimes cited as a concern compared to Japanese competitors.
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