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Chrysler Neon 2001 2002 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Neon Year: 2001-2002 Generation Generation Designation: Second Generation (PL) Codes Chassis Code: PL 👋 Introduction Market Position Market Position Description: The Chrysler Neon,...
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Chrysler Neon 2001 2002 Workshop Repair Service ManualChrysler Neon 2001 2002 Workshop Repair Service ManualChrysler Neon 2001 2002 Workshop Repair Service ManualChrysler Neon 2001 2002 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Neon
Year:
2001-2002
Generation
Generation Designation:
Second Generation (PL)
Codes
Chassis Code:
PL
👋 Introduction
Market Position
Market Position Description:
The Chrysler Neon, particularly the second generation (PL), was positioned as an affordable compact car, competing with models like the Honda Civic, Toyota Corolla, and Ford Focus. It aimed to offer a blend of practicality, fuel efficiency, and a somewhat engaging driving experience, often at a competitive price point.
Competitive Analysis
Competitive Analysis Summary:
The Neon's strengths included its relatively spacious interior for its class and peppy engine options. However, it faced stiff competition from established Japanese and American rivals known for reliability and build quality. This manual is crucial for owners and technicians looking to maintain and repair these vehicles effectively, addressing potential quirks specific to the platform.
Key Features
Key Features Vehicle:
The second-generation Neon (PL) featured a redesigned exterior and interior compared to its predecessor, with improved aerodynamics and a more modern aesthetic. It offered both coupe and sedan body styles and was known for its accessible pricing and decent performance for its segment.
📋 Manual Details
Coverage Areas
Coverage Areas List:
• Engine
• Transmission (Manual & Automatic)
• Drivetrain
• Suspension
• Steering
• Brakes
• Electrical System
• HVAC
• Fuel System
• Exhaust System
• Cooling System
• Body and Frame
• Interior Systems
• Troubleshooting
• Diagnostic Procedures
• Wiring Diagrams
• Specifications
• Maintenance Schedules
• Emissions Control
Page Count
Estimated Page Count:
Approx. 1500-2000+
Manual Type
Manual Type:
Official Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Systems Covered Detailed:
Comprehensive coverage across all major vehicle systems, including engine mechanicals (timing, valve train, lubrication, cooling), fuel injection and delivery, ignition system, exhaust and emission controls, manual and automatic transmissions, clutch, drive axles, suspension components (struts, springs, control arms), steering gear and linkage, hydraulic brake system (ABS if applicable), power steering, charging system (alternator, battery), starting system, lighting, instrumentation, body electricals, climate control (HVAC), power accessories (windows, locks, mirrors), and chassis components.
Procedures Included
Procedures Included List:
• Routine Maintenance
• Scheduled Servicing
• Component Removal and Installation
• Disassembly and Reassembly
• Diagnosis and Troubleshooting
• Component Testing
• Wiring Diagram Interpretation
• Diagnostic Trouble Code (DTC) analysis
• Torque Specifications
• Fluid Level Checks and Changes
• Brake Bleeding
• Wheel Alignment Procedures
• Engine Performance Tuning
• Electrical Component Repair
• Body Panel Repair
Technical Depth
Technical Depth Description:
In-depth technical information suitable for professional technicians and experienced DIY enthusiasts. Includes detailed diagnostic flowcharts, specifications for critical components, step-by-step repair procedures, rebuild instructions, and advanced troubleshooting techniques. Covers both mechanical and electrical aspects of the vehicle.
📊 Manual Specifications
File Format
File Format Details:
Searchable PDF with high-resolution diagrams and illustrations. Optimized for digital viewing and printing of specific sections.
Print Quality
Print Quality Description:
Digitally rendered with clarity for all diagrams, schematics, and text, ensuring readability when printed.
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Primary Engine Options:
• 2.0L SOHC I4 (16-valve) - Engine Code: ECC
• 2.0L DOHC I4 (16-valve) - Engine Code: ESX (High Output for R/T models)
Performance
Performance Figures:
SOHC: Approx. 132 hp @ 5600 rpm, 130 lb-ft @ 4800 rpm. DOHC: Approx. 150 hp @ 6000 rpm, 135 lb-ft @ 4800 rpm. (Figures are approximate and can vary slightly by source and specific tuning).
Fuel System
Fuel System Description:
Electronic Multi-Point Fuel Injection (MPI) with integrated fuel pump, fuel filter, and returnless fuel rail (on some configurations).
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual Transmission
Optional
Optional Transmission:
4-speed Automatic Transmission (41TE)
Features
Transmission Features:
Manual transmission features a standard clutch assembly. Automatic transmission includes torque converter and electronic control for shifting.
📐 Dimensions
Exterior
Exterior Dimensions:
Length: ~174.4 inches, Width: ~67.4 inches, Height: ~55.7 inches (Sedan); ~54.3 inches (Coupe). Wheelbase: ~104.0 inches.
Interior
Interior Dimensions:
Front Headroom: ~39.2 inches, Rear Headroom: ~37.4 inches. Front Legroom: ~42.0 inches, Rear Legroom: ~33.6 inches. (Approximate figures, may vary slightly by body style).
Cargo
Cargo Capacity:
Trunk Volume: ~13.0 cubic feet (Sedan). Folding rear seats (on some trims) increase utility.
Weights
Curb Weight:
Approx. 2750-3000 lbs, depending on configuration and options.
🛡️ Safety Features
Ratings
NHTSA Ratings:
NHTSA frontal impact ratings for this generation generally showed good protection for the driver and front passenger, though side impact protection was more variable. Specific year/model testing results should be consulted.
Active Features
Active Safety Features:
Front disc brakes, rear drum brakes (ABS optional on some models), power-assisted steering.
Passive Features
Passive Safety Features:
Driver and front passenger airbags, crumple zones, side-impact door beams, three-point seat belts with pretensioners.
💡 Technology Features
Infotainment
Infotainment Systems:
Basic AM/FM radio with cassette player or CD player. Optional premium audio systems may have been available. Limited integration compared to modern vehicles.
Driver Assistance
Driver Assistance Features:
ABS (Anti-lock Braking System) was optional on many models. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist were available.
Connectivity
Connectivity Features:
Limited connectivity, primarily featuring standard audio inputs. No Bluetooth or USB connectivity was standard on these models.
🔧 Maintenance
Service Intervals
Typical Service Intervals:
Oil Change: Every 5,000-7,500 miles or 6 months. Tire Rotation: Every 7,500 miles. Air Filter: Every 30,000 miles. Spark Plugs: Every 60,000-100,000 miles (depending on type). Timing Belt (ECC engine): Crucial, typically every 70,000-90,000 miles or 7 years. Transmission Fluid: Every 30,000-60,000 miles. Coolant: Every 30,000-100,000 miles (depending on coolant type).
Fluid Specifications
Fluid Specifications List:
• Engine Oil: SAE 5W-30 (API Certified, ILSAC GF-3 or higher)
• Automatic Transmission Fluid (ATF): ATF+4 (MS-9602)
• Manual Transmission Fluid: API GL-4 (75W-90 or 80W-90)
• Brake Fluid: DOT 3
• Power Steering Fluid: ATF+4 (MS-9602) or specified Mopar fluid
• Engine Coolant: HOAT (Hybrid Organic Additive Technology) or OAT (Organic Additive Technology) Antifreeze/Coolant (Chrysler spec)
Known Issues
Common Issues And Tips:
Common issues can include head gasket failures (especially with the ECC engine if maintenance is neglected), interior trim wear, occasional electrical gremlins (e.g., power window motors, gauge cluster issues), clutch wear, and suspension component wear. The manual provides detailed procedures for diagnosing and repairing these common problems. Paying close attention to the timing belt maintenance on the ECC engine is critical to prevent catastrophic engine failure.
📚 Vehicle History
Brand Heritage
Brand Heritage Context:
Chrysler, as part of DaimlerChrysler during this period, aimed to expand its compact car offerings and compete in a global market. The Neon was a significant product in this effort, representing a shift towards more modern platform development.
Model Evolution
Model Evolution Summary:
The second generation (PL) Neon, introduced for 2000, was a substantial redesign of the original Neon. It featured a more refined chassis, updated styling, and improved interior ergonomics. Key performance variants included the ACR (American Club Racer) and R/T, which offered enhanced handling and power.
Production
Production Years:
2000-2005 (Second Generation). This manual specifically covers the 2001 and 2002 model years.
🏆 Awards & Recognition
Recognitions
Recognitions And Ratings:
The Neon, particularly the second generation, received mixed reviews from automotive journalists. While praised for its handling and performance in certain trims (like the R/T), it was often criticized for interior material quality and some reliability concerns compared to segment leaders. It did not achieve major recurring awards but was a significant player in the budget-friendly compact car market of its era.
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