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Dodge Neon 2002 2003 2004 2005 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Neon Model Generations: Second Generation (PL) Model Years Covered: 2002, 2003, 2004, 2005 Codes Chassis Codes: PL 👋 Introduction Market Position Segment: Compact...
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Dodge Neon 2002 2003 2004 2005 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Neon
Model Generations:
Second Generation (PL)
Model Years Covered:
2002, 2003, 2004, 2005
Codes
Chassis Codes:
PL
👋 Introduction
Market Position
Segment:
Compact Car
Target Audience:
DIY enthusiasts, independent repair shops, Dodge Neon owners seeking in-depth repair and maintenance information.
Competitive Analysis
Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier.
Key Features
Value Proposition:
Provides factory-level diagnostic and repair procedures for all major systems, saving time and money on vehicle maintenance and repairs.
Delivery Method:
Instant Download - Digital PDF, no shipping or waiting time.
📋 Manual Details
Coverage Areas
Primary Coverage:
North America (USA, Canada, Mexico)
Page Count
Total Pages:
1652
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (2.0L SOHC, 2.0L DOHC), Transmission (Manual & Automatic), Drivetrain, Exhaust System
Chassis:
Suspension (Front & Rear), Steering, Brakes (Front Disc, Rear Drum/Disc), Wheels & Tires
Electrical:
Body Electrical Systems, Powertrain Control Module (PCM), Ignition System, Lighting, Instrument Panel, Audio Systems, HVAC Controls, Power Accessories
Body:
Body & Frame, Exterior Trim, Interior Trim, Doors, Glass, Seats, HVAC Components, Emissions System (partial coverage)
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks & Top-offs, Tune-ups
Repair:
Engine Overhaul, Transmission Rebuilds, Brake Pad/Rotor Replacement, Suspension Component Replacement, Electrical Component Diagnosis & Repair, Body Panel Repair
Diagnostics:
Troubleshooting Charts, Diagnostic Trouble Codes (DTCs), Electrical Schematics, Symptom-based Diagnostics
Troubleshooting Engine:
Detailed diagnosis for starting issues, rough idling, misfires, oil pressure problems, overheating, and emissions related faults.
Troubleshooting Transmission:
Diagnosis for hard shifting, slipping, fluid leaks, and electronic control issues in automatic transmissions. Clutch and linkage issues for manuals.
Electrical Schematics:
Comprehensive wiring diagrams for all major vehicle systems including engine control, lighting, power windows, door locks, and more.
Technical Depth
Depth:
Comprehensive from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.
Engine Rebuild:
Includes detailed steps for cylinder head removal and reassembly, piston and connecting rod installation, crankshaft and bearing service, timing belt replacement and alignment.
Suspension Repair:
Procedures for strut and shock absorber replacement, control arm and ball joint servicing, sway bar link replacement, and wheel bearing replacement.
📊 Manual Specifications
File Format
Quality:
High-resolution PDF, text-searchable, printable pages.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
ECC (2.0L SOHC I4)
Engine Description 1:
16-valve, Single Overhead Camshaft, Multi-Point Fuel Injection
Displacement 1:
1996 cc (121.8 cu in)
Horsepower 1:
132 hp @ 5600 rpm
Torque 1:
130 lb-ft @ 3200 rpm
Engine Variants
Engine Code 2:
AEB (2.0L DOHC I4)
Engine Description 2:
16-valve, Dual Overhead Camshaft, Multi-Point Fuel Injection
Displacement 2:
1996 cc (121.8 cu in)
Horsepower 2:
145 hp @ 6400 rpm
Torque 2:
135 lb-ft @ 4800 rpm
Fuel System
Fuel Delivery:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 octane recommended)
Ignition System
Ignition Type:
Distributorless Ignition System (DIS)
Engine Components
Timing Belt:
Belt driven (2.0L SOHC & DOHC). Replacement recommended at 75,000-100,000 mile intervals.
🔧 Transmission
Standard
Transmission Type Std:
Getrag 285 5-Speed Manual
Optional
Transmission Type Opt:
Chrysler 41TE 4-Speed Automatic
Features
Automatic Features:
Electronically Controlled with Overdrive
Fluid Specifications
Manual Fluid:
MS-9224 (API GL-4, SAE 75W-90 Synthetic)
Automatic Fluid:
ATF+4 (MS-9602) equivalent
📐 Dimensions
Exterior
Wheelbase:
104.4 inches (2652 mm)
Length:
170.4 inches (4328 mm)
Width:
67.4 inches (1712 mm)
Height:
55.2 inches (1402 mm)
Weights
Curb Weight Approx:
2750 - 2950 lbs (1247 - 1338 kg) - varies by trim and powertrain
Wheels Tires
Standard Tire Size:
P185/70R14 or P195/60R15 (depending on trim)
Wheel Bolt Pattern:
5 x 100 mm
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
3 Stars (2002 Model)
Active Features
Brakes:
Front Ventilated Disc, Rear Drum (standard). Optional ABS (Anti-lock Braking System) available.
Passive Features
Airbags:
Driver and Passenger Frontal Airbags (standard). Optional Side Curtain Airbags (rare).
Seat Belts:
3-point front seat belts with pretensioners, 3-point rear seat belts.
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player or cassette player. Optional premium audio systems available.
Dashboard Controls:
Manual HVAC controls, analog gauges for speedometer, tachometer, fuel, and temperature. Indicators for warning lights.
Driver Assistance
Cruise Control:
Optional on most trims.
Connectivity
Auxiliary Input:
Not typically equipped from the factory; aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6 months, whichever comes first, using synthetic blend or full synthetic oil.
Engine Coolant Change:
Every 30,000 - 50,000 miles (48,000 - 80,000 km) or 2-3 years.
Transmission Fluid Change:
Manual: Inspect every 30,000 miles; Automatic: Every 30,000-60,000 miles (depending on driving conditions).
Spark Plug Replacement:
Approximately 100,000 miles (for platinum or iridium plugs).
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (API SN or newer)
Coolant Type:
Mopar OAT (Organic Additive Technology) Antifreeze/Coolant (or equivalent)
Brake Fluid Type:
DOT 3
Power Steering Fluid:
ATF+4 (MS-9602) or Chrysler power steering fluid.
Known Issues
Engine Oil Consumption:
Some engines, particularly the 2.0L DOHC, can consume oil. Regular checks are essential. Piston ring issues are a potential cause.
Transmission Issues:
Automatic transmissions can experience shifting problems or premature wear. Manual transmissions are generally robust but clutch wear is normal.
Suspension Wear:
Worn control arm bushings, ball joints, and struts are common with mileage, leading to noise and poor handling.
Electrical Gremlins:
Faulty window regulators, power locks, and intermittent dashboard lights can occur due to wiring issues or module failures.
Exhaust System:
Rust and corrosion on exhaust components, including the catalytic converter and mufflers, are common in rust-belt regions.
📚 Vehicle History
Brand Heritage
Brand History:
Dodge, an American automotive brand, has a long history of producing a wide range of vehicles, known for its sporty and performance-oriented models.
Model Evolution
Neon Generations:
First Generation (1995-1999), Second Generation (2000-2005). This manual covers the second generation.
Second Gen Updates:
The second generation (PL platform) introduced a redesigned exterior, improved interior, and updated powertrains, including the SRT-4 variant later in its run (though this manual focuses on standard models).
Production
Manufacturing Location:
Belvidere Assembly Plant, Belvidere, Illinois, USA
Production Period:
2000-2005 for the second generation.
🏆 Awards & Recognition
Recognitions
Past Awards:
The Dodge Neon, particularly in its early generations, received some positive reviews for its value and handling. This manual supports owners maintaining those attributes.
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