Chrysler Neon 2002-2005 Service Repair Workshop Manual

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Basic Information Identification Make: Chrysler Model: Neon Generation: Second Generation (PL) Applicable Years: 2002, 2003, 2004, 2005 Codes Chassis Code: PL Introduction Market Position Target Audience: Owners with basic mechanical...

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标签: 2002 2003 2004 2005 Car Cars Chrysler Neon

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Description

Basic Information
Identification
Make:	Chrysler
Model:	Neon
Generation:	Second Generation (PL)
Applicable Years:	2002, 2003, 2004, 2005
Codes
Chassis Code:	PL

Introduction
Market Position
Target Audience:	Owners with basic mechanical skills and independent auto service professionals.
Competitive Analysis
Value Proposition:	Enables owners to perform repairs and maintenance themselves, saving significant costs compared to dealership services.
Key Features
Visual Aids:	Includes diagrams and illustrations for clarity.
Content Accuracy:	Vehicle-specific and contains the same technical data used by dealership technicians.
Accessibility:	Downloadable PDF format for easy viewing on various devices and printable pages.

Manual Details
Coverage Areas
Systems Covered:	['General Information', 'Engine Mechanical System', 'Engine Electrical System', 'Emission Control System', 'Fuel System', 'Clutch System', 'Manual Transaxle System', 'Automatic Transaxle System', 'Driveshaft and Axle', 'Suspension System', 'Steering System', 'Restraint System', 'Brake System', 'Body (Interior and Exterior)', 'Body Electrical System', 'Heating, Ventilation, Air Conditioning (HVAC)']
Procedures Included:	['Step-by-step repair instructions', 'Troubleshooting guides', 'Diagnostic procedures', 'Maintenance schedules', 'Component removal and installation', 'Wiring schematics', 'Specifications and measurements']
Page Count
Estimated Page Count:	Extensive (specific number not provided, typical for comprehensive workshop manuals)
Manual Type
Type:	Service Repair Workshop Manual
Language
Language:	English
Format
Format:	PDF Download

Manual Coverage
Systems Covered
Engine Mechanical:	Detailed coverage of engine components, timing, cylinder head, block, lubrication, cooling systems, and more.
Engine Electrical:	Includes ignition system, charging system, starting system, sensors, actuators, and engine control module (ECM) diagnostics.
Emission Control:	Covers emissions systems, catalytic converter, oxygen sensors, EGR system, and evaporative emission control (EVAP).
Fuel System:	Details fuel injection system, fuel pump, injectors, fuel filter, fuel pressure regulator, and tank.
Transmission Manual:	Comprehensive repair and maintenance procedures for the manual transaxle, including clutch operation and replacement.
Transmission Automatic:	Detailed service information for the automatic transaxle, including fluid, valve body, and torque converter procedures.
Drivetrain:	Covers driveshafts, CV joints, axle shafts, and wheel bearings.
Suspension:	Information on front and rear suspension components, shock absorbers, struts, control arms, and alignment procedures.
Steering:	Covers steering column, power steering system, rack and pinion, and tie rod ends.
Brakes:	Detailed coverage of hydraulic brake system, ABS, disc brakes, drum brakes (if applicable), and brake fluid.
Body Interior Exterior:	Includes body panel removal/installation, door mechanisms, interior trim, and glass.
Body Electrical:	Coverage of lighting, wipers, power windows, power locks, instruments, and accessory circuits.
HVAC:	Details air conditioning system, heater core, blower motor, climate controls, and refrigerant handling.
Restraint System:	Information on airbags, seat belts, and associated sensors and modules.
Technical Depth
Depth:	Comprehensive diagnostic, repair, and maintenance procedures suitable for professional mechanics and advanced DIYers.
Information Source:	Vehicle Specific (Exact same information used by authorized dealer service departments)

Manual Specifications
File Format
Format:	PDF
Compatibility:	All Versions of Windows and Mac
Requirements:	Adobe PDF Reader
Print Quality
Printability:	All pages are printable
Binding Type
Binding:	N/A (Digital PDF)
Paper Type
Paper Type:	N/A (Digital PDF)

Engine Specifications
Primary Engine
Engine Type:	Inline 4-Cylinder (SOHC and DOHC variants common for this generation)
Displacement:	2.0L (1996 cc)
Engine Code Examples:	ECC, EDZ (2.0L SOHC), AGT (2.0L DOHC - ACR trim)
Performance
Horsepower Range:	Approximately 132 hp (SOHC) to 150 hp (DOHC ACR)
Torque Range:	Approximately 130 lb-ft (SOHC) to 130 lb-ft (DOHC ACR)
Fuel System
Induction:	Multi-point Fuel Injection (MPI)
Fuel Type:	Unleaded Gasoline

Transmission
Standard
Transmission Type Std:	5-Speed Manual Transaxle
Optional
Transmission Type Opt:	4-Speed Automatic Transaxle
Features
Clutch Type:	Dry Single Plate (Manual)

Dimensions
Exterior
Body Styles:	2-door Coupe, 4-door Sedan
Wheelbase:	Approx. 104.1 inches (2644 mm)
Length:	Approx. 174.4 inches (4430 mm) Sedan / 170.5 inches (4331 mm) Coupe
Width:	Approx. 67.7 inches (1720 mm)
Height:	Approx. 55.0 inches (1397 mm) Sedan / 53.2 inches (1351 mm) Coupe
Weights
Curb Weight Range:	Approx. 2700 - 2900 lbs (1225 - 1315 kg), depending on body style and transmission

Safety Features
Ratings
NHTSA Frontal Crash Test Driver:	Good (2002-2003 models, though ratings can vary slightly by year)
NHTSA Frontal Crash Test Passenger:	Good (2002-2003 models)
Active Features
ABS:	Available (Standard on some higher trims, optional on others)
Passive Features
Airbags:	Standard front airbags. Side airbags available on some trims.
Seat Belts:	Front pretensioner seat belts.

Technology Features
Infotainment
Audio System:	Factory AM/FM stereo with CD player or cassette player depending on trim. Optional Infinity sound system.
Driver Assistance
Cruise Control:	Standard on most trims.
Connectivity
Power Accessories:	Power windows, power door locks, power mirrors available on higher trims.

Maintenance
Service Intervals
Oil Change Interval:	Typically every 7,500 miles or 6 months, using synthetic blend or full synthetic oil (refer to manual for exact specification).
Tire Rotation Interval:	Every 7,500 miles
Spark Plug Replacement:	Refer to manual, typically around 100,000 miles for platinum-tipped plugs.
Fluid Specifications
Engine Oil Type:	SAE 5W-30 (API certified, consult manual for specific certification and synthetic requirements)
Coolant Type:	Chrysler HOAT (Hybrid Organic Acid Technology) coolant or equivalent (typically Mopar OAT).
Transmission Fluid Manual:	API GL-4, SAE 75W-90 synthetic gear lubricant.
Transmission Fluid Automatic:	Chrysler ATF+4 (Mopar Automatic Transmission Fluid).
Brake Fluid Type:	DOT 3
Known Issues
Common Wear Items:	Control arm bushings, front struts/shocks, oxygen sensors, evaporative emission control (EVAP) system components.
Engine Performance Issues:	Carbon buildup on intake valves (especially with DOHC engines), coil pack failure.
Electrical Quirks:	Occasional issues with power window regulators, dashboard illumination.

Vehicle History
Brand Heritage
Brand:	Chrysler, a division of Fiat Chrysler Automobiles (FCA) at the time of this generation's production.
Model Evolution
Generation Introduction:	The second generation Neon (PL) was introduced for the 2000 model year and continued through 2005, with significant updates in this 2002-2005 timeframe.
Design Changes 2003:	Minor styling updates and revised interior for the 2003 model year, including improved materials and ergonomics.
Production
Manufacturing Location:	Belvidere, Illinois, USA
Production End:	Production for the North American market concluded with the 2005 model year. The Neon nameplate was later revived for different models in other markets.

Awards & Recognition
Recognitions
Previous Generation Recognition:	While the second generation (PL) itself did not receive major accolades like its critically acclaimed first generation, it represented a refinement of the Neon platform.