Dodge Neon 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Neon Year: 2004 Generation: Second Generation (PL) - Facelift Codes Platform Code: PL 👋 Introduction Market Position Vehicle Segment: Compact Car Brand Perception:...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Year:

Generation:

Second Generation (PL) - Facelift

Codes

Platform Code:

👋 Introduction

Market Position

Vehicle Segment:

Compact Car

Brand Perception:

Affordable, spirited performance, often targeted at younger buyers and enthusiasts.

Competitive Analysis

Key Competitors:

Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier/Cobalt, Mazda3.

Key Features

Chassis Design:

Known for its responsive handling and sporty feel, particularly for its price point.

Engine Options:

Primarily the 2.0L SOHC and DOHC engines, offering a good balance of performance and economy.

Trim Levels:

Typically included SE, SXT, and performance-oriented SRT-4 variants.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Manual

Language:

English

Format:

Digital (likely PDF, given the description's implied usability)

Page Count

Estimated Page Count:

1500+

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, disassembly, assembly, inspection, and torque specifications for all internal and external engine components.

Engine Performance:

Diagnosis and repair of performance issues, fuel delivery, ignition system, emissions controls, and engine management systems.

Transmission Manual:

Overhaul, inspection, repair, and adjustment procedures for the Getrag MS-R500 5-speed manual transmission.

Transmission Automatic:

Diagnosis, repair, and fluid service for the Chrysler A604 (41TE) 4-speed automatic transaxle.

Brake System:

Front and rear disc brake systems, ABS components, hydraulic lines, and parking brake.

Steering System:

Power steering system, steering column, steering gear, and linkage components.

Suspension System:

Front MacPherson strut and rear independent suspension (Multi-link or Torsion beam depending on model variant), shock absorbers, springs, control arms, and alignment procedures.

Electrical System:

Complete wiring diagrams, component locations, diagnostic procedures, fuse box layouts, lighting, charging system, starting system, and body electrical components.

HVAC System:

Air conditioning, heating, ventilation, blower motor, refrigerant system, and climate control panel.

Fuel System:

Fuel tank, fuel pump, fuel injectors, fuel filter, and evaporative emission control (EVAP) system.

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, and piping.

Cooling System:

Radiator, water pump, thermostat, cooling fans, and coolant specifications.

Body And Frame:

Exterior panel removal and installation, glass, doors, bumpers, and structural components.

Interior:

Dashboard removal, trim panels, seats, airbags, and interior components.

Procedures Included

Scheduled Maintenance:

Detailed descriptions of all routine maintenance tasks and recommended intervals.

Troubleshooting Guides:

Systematic diagnostic procedures for common and uncommon problems, including symptom-based troubleshooting.

Repair Procedures:

Step-by-step instructions for component replacement, adjustment, and overhaul for every major system.

Diagnostic Charts:

Fault code diagnosis and interpretation for Powertrain Control Module (PCM) and other vehicle modules.

Torque Specifications:

Precise torque values for all fasteners and critical assembly points.

Alignment Specifications:

Wheel alignment angles (camber, caster, toe) for front and rear axles.

Fluid Capacities And Types:

Exact fluid types and quantities for engine oil, coolant, transmission fluid, brake fluid, power steering fluid, and windshield washer fluid.

Refrigerant Handling:

Procedures for safe charging and recovery of R-134a refrigerant for the A/C system.

Technical Depth

Depth Of Coverage:

Comprehensive: Covers everything from basic fluid changes and filter replacements to full engine and transmission rebuilds, complex electrical diagnostics, and body repairs.

Diagnostic Tools:

Information necessary for using OBD-II scan tools, multimeters, and specialized diagnostic equipment.

📊 Manual Specifications

File Format

File Type:

Searchable Text:

Yes (assuming a professionally created digital manual)

Printable:

Print Quality

Diagram Clarity:

High (expected for factory service manuals)

Image Resolution:

High (expected for factory service manuals)

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code Sohc:

2.0L (122 cu in) SOHC I4 (GEMA/C PowerTech)

Engine Code DOHc:

2.0L (122 cu in) DOHC I4 (4G63 variant/Chrysler PowerTech)

Performance

Sohc Horsepower:

132 hp @ 5800 rpm

Sohc Torque:

130 lb-ft @ 4400 rpm

DOHc Horsepower:

145 hp @ 6400 rpm

DOHc Torque:

135 lb-ft @ 4800 rpm

Srt4 Horsepower:

205 hp @ 5600 rpm (2.4L Turbocharged)

Srt4 Torque:

230 lb-ft @ 4000 rpm (2.4L Turbocharged)

Fuel System

Fuel Type:

Unleaded gasoline

Fuel Delivery:

Multi-point fuel injection (MPI)

Engine Components

Timing Drive:

SOHC: Timing Belt; DOHC: Timing Belt

Engine Oil

Oil Type Sohc DOHc:

SAE 5W-30 (API certified, synthetic or synthetic blend recommended)

Oil Capacity Sohc DOHc:

4.5 quarts (4.3 liters) with filter

🔧 Transmission

Standard

Standard Transmission:

Getrag MS-R500 5-speed manual transmission (standard on most models)

Optional

Optional Transmission:

Chrysler A604 (41TE) 4-speed automatic transaxle (optional on some models)

Features

Manual Gear Ratios:

Specific ratios would be detailed in the manual, but typical for compact cars of the era.

Automatic Features:

Electronically controlled, with torque converter lock-up.

Fluid Specifications Automatic

Automatic Transmission Fluid Type:

ATF+4 (Mopar)

Fluid Capacity Automatic

Automatic Transmission Fluid Capacity:

Approx. 5.5 quarts (5.2 liters) for refill

📐 Dimensions

Exterior

Length:

Approx. 173.5 inches (440.7 mm)

Width:

Approx. 67.4 inches (1712 mm)

Height:

Approx. 53.4 inches (1356 mm)

Wheelbase:

Approx. 104.1 inches (2644 mm)

Weights

Curb Weight:

Approx. 2600-2800 lbs (1179-1270 kg), depending on trim and options

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

4-star (for 2004 models with side airbags)

NHTSA Frontal Impact Passenger:

4-star (for 2004 models with side airbags)

NHTSA Side Impact Driver:

5-star (for 2004 models with side airbags)

NHTSA Side Impact Rear Passenger:

5-star (for 2004 models with side airbags)

Active Features

Available Anti-lock Braking System (ABS)

Passive Features

Airbags:

Driver and front passenger airbags; optional side-impact airbags.

Seatbelts:

3-point front seat belts with pretensioners, 3-point rear seat belts.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM CD player with optional Infinity premium audio system.

Display:

Digital clock and radio display; trip computer on some higher trims.

Driver Assistance

Cruise Control:

Standard on most trims.

Connectivity

Auxiliary Input:

Not standard; aftermarket solutions may exist.

🔧 Maintenance

Service Intervals

Engine Oil And Filter Change:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first (using synthetic blend or full synthetic oil).

Engine Coolant Change:

Initial change at 100,000 miles (160,000 km), then every 50,000 miles (80,000 km) or 5 years.

Transmission Fluid Change Automatic:

Check fluid level regularly; change every 60,000 miles (96,000 km) under normal conditions, or sooner under severe driving conditions.

Timing Belt Replacement:

Every 105,000 miles (170,000 km) or 7 years (critical item, failure can cause severe engine damage).

Fluid Specifications

Brake Fluid Type:

DOT 3 (or DOT 4 if specified by Chrysler)

Power Steering Fluid Type:

Mopar Power Steering Fluid (or equivalent generic power steering fluid compatible with Chrysler systems)

Known Issues

Common Issue 1:

Timing belt tensioner and idler pulley failure (preventative replacement is highly recommended with the belt).

Common Issue 2:

Rear axle bushings wear (can cause clunking or alignment issues).

Common Issue 3:

Coolant leaks, particularly from the water pump and thermostat housing.

Common Issue 4:

Automatic transmission issues (e.g., torque converter shudder, internal solenoid problems) on A604 units.

Common Issue 5:

Paint chipping and clear coat failure, especially on darker colors.

📚 Vehicle History

Brand Heritage

Parent Company:

Chrysler Group LLC (formerly DaimlerChrysler)

Model Evolution

Generation Introduction:

The second generation Neon (PL) was introduced for the 2000 model year. The 2003-2005 models represent a facelift with styling and mechanical updates.

Production

Manufacturing Location:

Belvidere, Illinois, USA

Production Years For Generation:

2000-2005

🏆 Awards & Recognition

Recognitions

Consumer Reports Ratings:

Variable, often criticized for reliability in earlier generations. However, specific year and engine combination ratings would need to be checked.