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DODGE NEON Service Repair Workshop Manual 2000-2005

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$16.99
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🏷️ Basic Information Identification Make: Dodge Model: Neon Model Years Covered: 2000, 2001, 2002, 2003, 2004, 2005 Codes Platform Code: PT Cruiser platform (P-body) 👋 Introduction Market Position Market Segment:...
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DODGE NEON Service Repair Workshop Manual 2000-2005
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Neon
Model Years Covered:
2000, 2001, 2002, 2003, 2004, 2005
Codes
Platform Code:
PT Cruiser platform (P-body)
👋 Introduction
Market Position
Market Segment:
Compact car, aimed at budget-conscious buyers and those seeking economical transportation.
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier, Hyundai Elantra.
Key Features
Design Philosophy:
Affordable, practical, with a focus on fuel efficiency and straightforward engineering, often praised for its sporty handling in certain trims.
Trim Levels:
Common trims include SE, SXT, ES, R/T, offering varying levels of equipment and performance. The R/T typically featured a more powerful engine and sport-tuned suspension.
Manual Value Proposition
Manual Quality Claim:
Positioned as the 'Best Manual Available On Tradebit!', emphasizing completeness and accuracy, contrasting with 'cheap, incomplete, inferior manuals'.
📋 Manual Details
Coverage Areas
Manual Type:
Service and Repair Workshop Manual
Language:
English
Format:
Digital (likely PDF, based on typical online sales)
Page Count
Page Count:
Not explicitly stated, but described as 'Complete Manual - No Missing Pages'
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, valvetrain, pistons, crankshaft, connecting rods, lubrication system, cooling system, fuel injection system, ignition system, exhaust system, emissions control systems.
Engine Electrical:
Starting system, charging system, ignition system, fuel injection control, diagnostic codes (OBD-II), sensors, actuators, powertrain control module (PCM) operation and testing.
Transmission Manual:
Manual transmission (e.g., Getrag MS-R500) internal components, clutch system, shift linkage, lubrication, removal and installation, troubleshooting.
Transmission Automatic:
Automatic transmission (e.g., Chrysler 41TE/42LE family) internal components, torque converter, valve body, hydraulic system, electronic controls, shift solenoids, removal and installation, troubleshooting, fluid specifications.
Brakes:
Front and rear brake systems (disc/drum or disc/disc), hydraulic system, master cylinder, brake lines, calipers, wheel cylinders, parking brake, ABS system (if equipped) operation, testing, and repair.
Steering:
Power steering system, steering gear/rack and pinion, steering column, tie rod ends, alignment specifications, troubleshooting.
Suspension:
Front and rear suspension components (struts, control arms, ball joints, sway bars, bushings), shock absorbers, springs, wheel bearing replacement, alignment specifications.
Electrical Body:
Interior and exterior lighting, power windows, power locks, mirrors, seats, wiper system, horn, instrument cluster, body control module (BCM) if applicable, fuses and relays, wiring diagrams.
HVAC:
Heating, ventilation, and air conditioning system components, refrigerant handling, compressor, condenser, evaporator, blower motor, climate controls, troubleshooting, recharging procedures.
Body And Frame:
Body panel removal and installation, door mechanisms, interior trim, exterior trim, glass replacement, rust repair, structural components.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements (oil, air, cabin), spark plug replacement, coolant flushes, brake fluid changes, transmission fluid changes, battery checks, tire rotation.
Troubleshooting:
Diagnostic procedures for common drivability issues, electrical faults, starting problems, braking issues, HVAC malfunctions, using diagnostic trouble codes (DTCs).
Repair And Rebuild:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for major vehicle systems.
Diagnostic Testing:
Procedures for testing sensors, actuators, electrical circuits, fuel pressure, ignition timing, and other critical system parameters.
Specifications And Tolerances:
Torque specifications for fasteners, alignment angles, fluid capacities, engine clearances, brake component dimensions, and other critical repair data.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all vehicle systems, essential for diagnosing electrical faults.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to major component overhaul and advanced diagnostics. Suitable for DIY enthusiasts and professional technicians.
📊 Manual Specifications
File Format
File Format:
Likely PDF, optimized for digital viewing and printing.
Print Quality
Print Quality:
High-resolution scans or original digital files ensuring clarity of diagrams, text, and images.
Binding Type
Binding Type:
Not applicable for digital format; if a print version is offered, binding would typically be comb or spiral for ease of use.
Paper Type
Paper Type:
Not applicable for digital format.
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
2.0L SOHC I4 (16-valve) 'Chrysler 10"' engine. Common engine codes include A67, or similar.
Displacement:
1996 cc (2.0 Liters)
Bore X Stroke:
87.5 mm x 83.0 mm
Compression Ratio:
9.4:1 (typical for SOHC)
Horsepower Output:
Approximately 132 hp @ 5600 rpm (for SOHC models)
Torque Output:
Approximately 130 lb-ft @ 4400 rpm (for SOHC models)
Performance
Engine Performance Variants:
Higher-output 2.0L DOHC Turbocharged engine found in R/T models (approx. 180-200 hp, depending on year and specific tune).
Fuel System
Fuel Delivery:
Electronic Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline, 87 octane recommended (higher octane may be recommended for R/T Turbo).
Fuel Tank Capacity:
Approximately 13.0 gallons (49 Liters)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission (Getrag MS-R500 or similar)
Optional
Transmission Type Optional:
4-speed Automatic Transmission (Chrysler 41TE/42LE family)
Features
Transmission Features:
Automatic transmission may include electronic control, adaptive shift logic depending on trim and year. Manual transmission features a single-plate dry clutch.
📐 Dimensions
Exterior
Length:
Approximately 174.4 inches (4430 mm)
Width:
Approximately 67.7 inches (1720 mm)
Height:
Approximately 53.8 inches (1367 mm)
Wheelbase:
Approximately 104.1 inches (2644 mm)
Front Track:
Approximately 58.0 inches (1473 mm)
Rear Track:
Approximately 58.3 inches (1481 mm)
Ground Clearance:
Typically around 5.0 - 5.5 inches (127 - 140 mm)
Cargo
Cargo Volume Sedan:
Approximately 13.0 cubic feet (0.37 cubic meters)
Cargo Volume Hatchback:
Approximately 42.4 cubic feet (1.20 cubic meters) with rear seats folded
Weights
Curb Weight:
Approximately 2700 - 2900 lbs (1225 - 1315 kg), varies by trim and equipment.
Gross Vehicle Weight Rating:
Typically around 3800 lbs (1724 kg).
Towing Capacity:
Not officially rated for towing. Not recommended.
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
4 out of 5 stars for manual transmission models, 3 out of 5 stars for automatic models (NHTSA data for similar era vehicles).
IIHS Crash Test Results:
Generally received 'Acceptable' to 'Good' ratings in frontal offset tests during its production run, depending on specific model year and year of testing.
Active Features
ABS:
Anti-lock Braking System (ABS) was typically optional or standard on higher trims.
Traction Control:
Traction control was often optional or part of a package, particularly on performance-oriented models like the R/T.
Passive Features
Airbags:
Driver and front passenger airbags were standard. Side airbags were often optional or unavailable.
Seatbelts:
Three-point seatbelts for all occupants, with pretensioners for front seats.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system was introduced and became more common throughout this generation.
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM radio with CD player or cassette player. Optional premium sound systems were available on higher trims. Auxiliary input was rare for this era.
Instrument Cluster:
Analog gauges for speedometer, tachometer (optional), fuel, coolant temperature. Warning lights for various systems. Some models featured a digital odometer.
Driver Assistance
Driver Assistance Features:
Limited driver assistance features typical for the era. ABS and traction control were the most advanced systems available, and often optional.
Connectivity
Connectivity Options:
Minimal connectivity. Some higher trims may have offered steering wheel audio controls. Bluetooth or USB ports were not standard.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first (using synthetic or synthetic blend oil). Refer to manual for conventional oil recommendations (often 3,000-5,000 miles).
Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed based on inspection.
Spark Plug Replacement:
Every 100,000 miles (160,000 km) for iridium-tipped plugs; check specific plug type for interval. Platinum plugs typically 60,000 miles.
Coolant Flush:
Every 5 years or 100,000 miles (160,000 km) for modern long-life coolants. Check manual for specific coolant type and initial fill interval.
Transmission Fluid Change Auto:
Every 60,000 miles (96,000 km) or 4 years. Check fluid level regularly.
Transmission Fluid Change Manual:
Every 60,000 miles (96,000 km) or 4 years.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 or 10W-30, API certified. Check manual for specific viscosity recommendations based on climate.
Engine Oil Capacity:
Approximately 4.0 US quarts (3.8 Liters) with filter change for 2.0L engine.
Coolant Type:
Chrysler/Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant or equivalent. Typically a pink or orange color.
Automatic Transmission Fluid:
Chrysler ATF+4 (or equivalent specification).
Manual Transmission Fluid:
API GL-3 or GL-4 gear oil, SAE 75W-90 or 80W-90. Check manual for specific recommendation.
Power Steering Fluid:
Chrysler/Mopar Power Steering Fluid or equivalent DEXRON III/MERCON compatible ATF.
Known Issues
Engine Issues:
Head gasket leaks (especially on early models), oil leaks from valve cover or oil pan, timing belt wear/failure (if equipped, though many used timing chains), occasional ignition coil or crank sensor failures.
Transmission Issues:
Automatic transmission solenoid failures leading to erratic shifting, manual transmission clutch wear, synchro ring issues in manual transmissions.
Suspension Issues:
Worn front control arm bushings, worn tie rod ends, premature strut wear, wheel bearing noise.
Electrical Issues:
Window regulator failures, power lock actuator failures, occasional dashboard warning light issues, HVAC blower motor resistor failure.
Brakes:
Brake pad and rotor wear, potential for sticky caliper pins.
📚 Vehicle History
Brand Heritage
Dodge Brand Context:
Dodge, as a division of Chrysler, historically focused on performance and sportier styling compared to its Plymouth or Chrysler counterparts, though the Neon was a mass-market compact.
Model Evolution
Second Generation Development:
The 2000-2005 Neon represents the second generation of the model. It was based on the Chrysler PT Cruiser platform (P-body) and featured a more refined interior and exterior design compared to the first generation.
Performance Variants:
The SRT-4 variant, introduced in 2003, became a cult performance icon, featuring a turbocharged 2.4L engine and significantly more power and track-focused tuning.
Production
Production Locations:
Primarily manufactured at the Belvidere Assembly Plant in Belvidere, Illinois, USA.
Production Years Global:
1994-2005 (First Gen: 1994-1999, Second Gen: 2000-2005)
🏆 Awards & Recognition
Recognitions
Editorial Awards:
The Neon, particularly the second generation, received mixed reviews. It was often praised for its value and handling for the price, but criticized for build quality and interior materials. It did not typically win major 'Car of the Year' awards but was a strong contender in the compact segment for value.
Performance Recognition:
The later SRT-4 variant gained significant recognition in enthusiast circles and automotive media for its impressive performance-to-price ratio and tuner potential.
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