Dodge Neon & SRT-4 2000–2005 Service & Repair Manual

This Dodge Neon and SRT-4 service manual contains 2004 PL/Neon service information, with separate engine and transaxle chapters, R/T-specific component details, and left- and right-hand-drive procedures where applicable.

PDF Search, Chapter Bookmarks, and Page Count

Search and navigation: The PDF has searchable text and 34 chapter bookmarks. Small wiring-diagram labels and connector details are clear when enlarged.

The ZIP contains one printable PDF with 1,652 pages, including 11 blank pages.

Engine Overhaul, Transaxles, and Chassis Repair

The following highlights are a selection of the contents. Additional topics include audio-system diagnosis and wiper/washer service.

• Engine repair: Engine removal, cylinder-head service, crankshaft and piston work, internal inspection, and timing-belt installation.
• Turbocharger diagnosis: Underboost, overboost, abnormal noise, and charge-air leaks, plus turbocharger replacement and intercooler, oil-line, coolant-line, and vacuum-harness service.
• Transaxle overhaul: T350, T850, and 40TE teardown, assembly, and adjustment, with hydraulic clutch service, manual-transaxle synchronizers, and automatic-transaxle pressure testing.
• Suspension and driveline: Strut disassembly, wheel-bearing replacement, lower-control-arm repair, rear lateral-arm and tension-strut service, and CV-joint boot replacement.
• Brakes and steering: Standard and SRT-4 brake hardware, rear disc and drum arrangements, Mark 20e ABS, steering-pump flow and pressure testing, and steering-gear replacement.
• Electrical diagnosis: System wiring diagrams, connector pin-outs, harness-location views, starting and charging tests, and DRB III module setup procedures.
• Cooling system: Leak diagnosis, pressure-cap testing, thermostat and water-pump replacement, radiator service, and fan-control information.

It is suited to readers with established automotive repair experience and access to workshop equipment; the overhaul and electronic procedures call for press tooling, measuring equipment, and DRB III scan-tool functions.

Maintenance, Suspension, and Alignment

Separate North American, export, and SRT-4 maintenance schedules distinguish routine use from severe-duty service. Fluid information covers level checks, drain-and-fill procedures, automatic-transaxle service versus overhaul capacities, and the SRT-4/T850 limited-slip additive requirement.

Suspension procedures distinguish the SRT-4 steering knuckle and hub assembly from the standard arrangement. ACR-specific inspection notes identify differences in certain strut components, including jounce-bumper inspection.

The manual explains why the original front lower ball joints are sealed for life and warns that attempts to add grease can damage their non-vented seals. Always verify load limits and use appropriately rated jack stands before getting under the vehicle to inspect these suspension parts.

Component-specific torque tables cover strut tower nuts, steering-knuckle fasteners, ball-joint pinch bolts, rear tension-strut bolts, lateral-arm nuts, and hub-bearing retainers. Metric and SAE specifications include additional tightening angles where required.

Factory alignment data covers camber, caster, total toe, and curb-height measurement. Strut-nut socket/wrench 6864, spring-compressor illustrations, and bearing-press setups help readers identify the equipment required before starting the job.

Internal Engine Repair and Turbocharger Faults

The internal-engine chapters cover 2.0L SOHC and 2.4L DOHC engines. References to the 1.6L engine occur in selected specifications and system procedures rather than a dedicated internal-engine overhaul chapter.

Engine diagnosis includes compression and cylinder-leakage tests, oil-pressure checks, and mechanical fault charts. Internal service extends to valve guides and seats, hydraulic lash adjusters, bearing-clearance measurement, piston-ring fitting, and oil-pump inspection.

The high-output R/T receives specific valve-spring and manifold details. The 2.4L chapter adds piston oil jets, oil-cooler service, and balance-shaft timing.

Turbocharger symptom charts connect boost and noise complaints with wastegate, surge-valve, control-hose, and intercooler-plumbing faults. These distinctions help readers separate a control or plumbing problem from a turbocharger replacement concern. The manual also warns that prolonged overboost can damage the engine.

Transaxle Repair Depth

Manual-unit procedures address differential adjustment and geartrain service, with fixture 8487 identified for T850 assembly work. The T350 output shaft is serviced as an assembly; its internal disassembly is not an approved repair procedure.

The automatic-transaxle repair chapter is labeled 40TE, while lubrication information also names the 41TE. Automatic-unit procedures cover clutch air-pressure tests, valve-body overhaul, clutch-pack clearances, and bearing-preload selection.

Fuel Delivery and Engine Controls

Fuel-system procedures cover fuel-pump-module replacement, filter/pressure-regulator service, fuel-rail and injector work, and fuel-tank removal. The pump itself is replaced with the module; the inlet strainer, regulator, and fuel-level sensor are separately serviceable.

Wiring Diagrams and Diagnostic Scope

The PL wiring section occupies 332 pages. Examples include Fuel/Ignition System, Ground Distribution, and Connector Pin-Outs, with separate connector and splice locations for left- and right-hand-drive vehicles.

Other illustrations include the turbocharger Vacuum Harness Schematic, ABS Mode Hydraulic Circuit, and 4XTE Transaxle Hydraulic Schematics.

Electronic procedures include DTC retrieval, PCM/SKIM programming, transaxle Quick Learn, and pinion-factor setting. The module-setup information helps readers account for programming and calibration work when planning a replacement.

Separate diagnostic publications are referenced for certain fault-code troubleshooting procedures; this service manual does not replace every powertrain, chassis, or body diagnostic volume.

HVAC and Body Service

HVAC coverage includes performance testing, refrigerant leak detection, recovery, evacuation, charging, and heater-core replacement. It distinguishes the variable-orifice arrangement on 2.0L left-hand-drive models from expansion-valve systems on 2.4L and right-hand-drive models.

Body repair information includes water-leak and wind-noise diagnosis, plastic-panel repair, glass replacement, and sunroof adjustment. Frame dimensions, body-opening measurements, weld locations, and structural-adhesive and sealer locations support more extensive body work.

A Preview of T850 Gear and Differential Checks

The T850 input-shaft specifications list third-gear end play of 0.099–0.505 mm and fourth-gear end play of 0.048–0.457 mm.

Differential turning torque is specified at 2.3–3.4 N·m with the geartrain removed and the differential-cover and bearing-plate fasteners installed and tightened. The adjustment section pairs this check with a differential-bearing shim chart.