2004 CHRYSLER NEON (PL PLATFORM) Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Neon Year: 2004 Codes Platform Code: PL 👋 Introduction Market Position Segment: Compact Car Target Audience: Budget-conscious consumers seeking affordable transportation. Competitive Analysis...

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标签: 2004 Car Cars Chrysler NEON

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Description

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Year:

Codes

Platform Code:

👋 Introduction

Market Position

Segment:

Compact Car

Target Audience:

Budget-conscious consumers seeking affordable transportation.

Competitive Analysis

Key Competitors:

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

Key Features

Body Styles:

2-door coupe, 4-door sedan.

Performance Focus:

Emphasis on economy and practical performance, with sporty variants available.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

Digital (PDF)

Page Count:

Approximately 1500-2000 pages (typical for a comprehensive service manual of this era)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

2.0L DOHC (ECC/EDZ) engine overhaul, diagnostics, timing belt, pistons, rings, bearings, cylinder head, valves, camshafts, crankshaft.

Engine Performance:

Fuel injection system, ignition system, emissions control systems (EVAP, EGR), engine control module (ECM) diagnostics and programming, sensor testing.

Transmission Manual:

NV1500 5-speed manual transmission overhaul, clutch replacement, gear ratios, shift linkage adjustments.

Transmission Automatic:

41TE 4-speed automatic transmission overhaul, torque converter, valve body, electronic controls, fluid specifications, shift diagnostics.

Brakes:

Front disc brakes (vented), rear drum brakes, ABS system diagnostics, brake fluid specifications, caliper and wheel cylinder overhaul, parking brake system.

Suspension Steering:

Front MacPherson strut suspension, rear multi-link suspension, power steering system, steering column, wheel alignment specifications, ball joints, tie rod ends.

Electrical Lighting:

12V battery system, charging system (alternator), starting system (starter motor), lighting circuits, fuses, relays, bulbs, exterior and interior lighting diagnostics.

Electrical Accessories:

Power windows, power locks, power mirrors, horn, wiper system, sunroof (if equipped), instrument cluster, HVAC blower motor, power antenna.

Body Chassis:

Body panel removal and installation, doors, hood, trunk lid, bumpers, glass replacement, interior trim removal, chassis component torque specifications.

HVAC:

Air conditioning system (R-134a refrigerant), heater core, evaporator, blower motor, HVAC controls, refrigerant charging procedures, leak detection.

Restraint Systems:

Airbag system diagnostics, SRS module, seat belt pre-tensioners, airbag sensor locations, troubleshooting.

Procedures Included

Routine Maintenance:

Oil change, filter replacement, tire rotation, fluid level checks, spark plug replacement, air filter replacement, fuel filter replacement.

Troubleshooting:

Diagnostic charts for common symptoms (e.g., hard starting, poor performance, electrical faults), DTC (Diagnostic Trouble Code) interpretation and resolution.

Engine Repair:

Complete engine rebuild procedures, cylinder head gasket replacement, piston ring replacement, bearing replacement, timing belt replacement.

Transmission Service:

Automatic and manual transmission fluid change intervals, filter replacement, seal replacement, internal component repair and overhaul.

Brake Service:

Brake pad and rotor replacement, brake shoe and drum adjustment, brake line replacement, ABS bleed procedures.

Suspension Steering Repair:

Strut and shock absorber replacement, control arm bushing replacement, power steering pump replacement, steering rack rebuild.

Electrical Diagnostics:

Wiring diagrams for all major systems, component testing procedures, circuit troubleshooting, charging system testing, starter testing.

HVAC Service:

Refrigerant system evacuation and recharge, leak detection, blower motor replacement, heater core replacement, A/C compressor replacement.

Body Work:

Panel alignment, door hinge adjustment, window regulator replacement, bumper repair and replacement, rust prevention and repair techniques.

Technical Depth

Depth Level:

Comprehensive: Covers everything from basic scheduled maintenance to complete engine and transmission overhauls, including detailed electrical diagnostics and body repair.

Diagnostic Tools:

Includes guidance on using OBD-II scanners, multimeter usage, and specific Chrysler diagnostic tools or procedures.

Torque Specifications:

Detailed torque specifications for critical fasteners across all systems.

Wiring Diagrams:

Comprehensive and system-specific wiring diagrams provided.

📊 Manual Specifications

File Format

File Type:

Searchability:

Fully searchable text content for quick information retrieval.

Printability:

Printable pages, allowing for easy use at the workbench.

Print Quality

Image Resolution:

High-resolution diagrams and illustrations for clarity.

Text Clarity:

Sharp and legible text, ensuring easy reading of instructions and specifications.

Binding Type

Binding Method:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code Primary:

EDZ / ECC

Engine Type:

Inline 4-cylinder

Displacement:

2.0 Liters (1996 cc)

Valvetrain:

DOHC (Double Overhead Camshaft), 16 Valves

Performance

Horsepower Std:

Approx. 132 hp @ 5600 RPM

Torque Std:

Approx. 130 lb-ft @ 4000 RPM

Fuel System

Fuel Delivery:

Multi-Port Fuel Injection (MPFI)

Fuel Type:

Unleaded gasoline (87 octane recommended)

Engine Management

ECM Type:

Chrysler NGC (Next Generation Controller) or earlier systems.

Cooling System

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) Extended Life Antifreeze (Orange)

🔧 Transmission

Standard

Transmission Type Std:

NV1500 5-Speed Manual

Optional

Transmission Type Opt:

41TE 4-Speed Automatic (with Overdrive)

Features

Automatic Transmission Control:

Electronically controlled with adaptive shift logic.

Fluid Specifications

Manual Transmission Fluid:

API GL-4 SAE 75W-90 Synthetic Gear Oil (e.g., Mopar Manual Transmission Lubricant)

Automatic Transmission Fluid:

ATF+4 (Automatic Transmission Fluid Type 4) (e.g., Mopar ATF+4)

📐 Dimensions

Exterior

Length Sedan:

Approx. 176.2 inches

Width:

Approx. 67.4 inches

Height Sedan:

Approx. 54.8 inches

Wheelbase:

Approx. 104.4 inches

Weights

Curb Weight Est Auto:

Approx. 2700-2900 lbs

Curb Weight Est Manual:

Approx. 2600-2800 lbs

Cargo

Trunk Volume Sedan:

Approx. 13.5 cu ft

Trunk Volume Coupe:

Approx. 12.1 cu ft

🛡️ Safety Features

Ratings

NHTSA Front Driver Side:

Not Rated (for this specific year, review available reports for similar years)

NHTSA Front Passenger Side:

Not Rated (for this specific year, review available reports for similar years)

IIHS Front Crash Rating:

Good (for similar models of this generation, refer to IIHS for exact 2004 data)

Active Features

Available (Anti-lock Braking System)

Passive Features

Airbags Standard:

Driver and Passenger front airbags

Seatbelts:

Three-point seatbelts with pretensioners for front occupants.

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with CD player (optional premium sound system).

Display:

Digital clock, basic radio display. No advanced touchscreen interfaces.

Driver Assistance

Cruise Control:

Standard on most trims.

Connectivity

Auxiliary Input:

Not typically equipped with standard auxiliary input; aftermarket solutions common.

🔧 Maintenance

Service Intervals

Oil Change Interval Synthetic:

7,500-10,000 miles or 12 months (with synthetic oil, consult manual for specific oil)

Oil Change Interval Conventional:

3,000-5,000 miles or 6 months (with conventional oil)

Timing Belt Replacement:

Every 100,000 miles or 7 years (critical component, interference engine)

Transmission Fluid Change Auto:

Every 30,000-60,000 miles, or as per severe driving conditions.

Fluid Specifications

Engine Oil Viscosity:

SAE 5W-30 (preferred) or SAE 10W-30

Engine Oil Capacity:

Approx. 4.0 quarts (with filter)

Brake Fluid Type:

DOT 3

Known Issues

Common Problem 1:

Timing belt tensioner failure, leading to belt damage or slippage.

Common Problem 2:

Intake manifold gasket leaks (plastic manifold).

Common Problem 3:

Oil leaks from valve cover gasket or oil pan gasket.

Common Problem 4:

Automatic transmission torque converter shudder or hard shifting.

Common Problem 5:

Power steering pump whine or leaks.

Common Problem 6:

Window regulator failures.

📚 Vehicle History

Brand Heritage

Brand Focus:

Chrysler, a division of DaimlerChrysler at the time, aimed to offer stylish and value-oriented vehicles.

Model Evolution

Generation:

Second Generation (2000-2006)

Platform Significance:

PL platform, shared with Dodge Neon and PT Cruiser variants.

Production

Manufacturing Location:

Belvidere, Illinois, USA

🏆 Awards & Recognition

Recognitions

Safety Awards:

Received mixed safety ratings across generations; consult specific year IIHS/NHTSA reports for 2004.

Value Recognition:

Often cited as a good value for its price point, offering decent features for the cost.