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Chrysler Voyager 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Year: 2004 Codes Platform Code: RS 👋 Introduction Market Position Vehicle Segment: Minivan Target Audience: Families, commercial use (taxi, shuttle services) Competitive Analysis Key Competitors: Dodge Grand Caravan, Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture. Key Features Notable Features: Spacious interior, versatile seating configurations, available Stow 'n Go seating (though not standard on all 2004 models, the platform supports it), power sliding doors, integrated rear entertainment systems (optional). Manual Value Proposition: Empowers owners and technicians with comprehensive, factory-accurate repair and maintenance information to ensure optimal performance and longevity. 📋 Manual Details Coverage Areas Markets Covered: North America, Europe (specific variants) Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Manual (FSM) Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: 2.4L DOHC I4, 3.3L OHV V6, 3.8L OHV V6: Engine mechanical, lubrication, cooling, fuel injection, ignition, emissions control, starting and charging, diagnosis and testing. Transmission Systems: 4-speed automatic transmission (A604, A670): Service, overhaul, diagnosis, fluid types, shift control. Drivetrain Systems: Front-wheel drive, CV axles, differential: Inspection, replacement, service. Suspension Systems: Front strut suspension, rear torsion beam axle: Component identification, inspection, alignment specifications, shock absorber replacement, control arm service. Steering Systems: Power rack and pinion: Steering column, power steering pump, lines, rack and pinion unit service, troubleshooting. Brake Systems: Front disc brakes, rear drum brakes (some models rear disc): System components, hydraulic service, bleeding procedures, rotor and pad replacement, parking brake service. Electrical Systems: Battery, starting, charging, lighting, ignition, instruments, power windows, locks, mirrors, wipers, horn, HVAC controls, radio, power sliding doors, power liftgate: Wiring diagrams, component testing, troubleshooting. Body And Chassis Systems: Body panels, doors, hood, liftgate, interior trim, seating, frame and underbody: Repair procedures, panel replacement, rust prevention, body hardware. HVAC Systems: Air conditioning, heating, ventilation: Component service, refrigerant handling, leak detection, control module diagnosis. Procedures Included Diagnostic Procedures: Troubleshooting guides based on symptoms, diagnostic trouble codes (DTCs), component testing procedures. Maintenance Procedures: Scheduled maintenance tasks, fluid changes, filter replacements, spark plug replacement, belt service, brake fluid flush. Repair Procedures: Step-by-step instructions for component removal, installation, and overhaul for all major vehicle systems. Troubleshooting Guides: Symptom-based diagnostic trees and component-specific testing. Electrical Troubleshooting: Detailed wiring diagrams, circuit descriptions, and component testing methods for all electrical systems. Technical Depth Depth: Comprehensive, from basic fluid checks to complete engine and transmission overhauls. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Binding Recommendation: Print and spiral-bind for ease of use in a workshop environment. Paper Type Recommended Paper: Durable, glossy paper for workshop conditions. ⚙️ Engine Specifications Primary Engine Engine Code 1: ECA Engine Description 1: 2.4L (2429cc) DOHC 16-valve Inline-4 (World Engine) Horsepower 1: 142 hp @ 5200 rpm Torque 1: 158 lb-ft @ 4000 rpm Optional Engine 1 Engine Code 2: EGW Engine Description 2: 3.3L (3301cc) OHV 12-valve V6 Horsepower 2: 180 hp @ 5000 rpm Torque 2: 205 lb-ft @ 3200 rpm Optional Engine 2 Engine Code 3: EGQ Engine Description 3: 3.8L (3778cc) OHV 12-valve V6 Horsepower 3: 197 hp @ 5200 rpm Torque 3: 230 lb-ft @ 4000 rpm Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded gasoline Recommended Octane: 87 (minimum) 🔧 Transmission Standard Transmission Type Std: 4-speed automatic (A604/A670) Optional Transmission Type Opt: Not applicable (standard across powertrain options) Features Transmission Features: Driver-adaptive electronic controls, selectable gear range (AutoStick on some trims for 3.8L). Fluid Specs Transmission Fluid Type: Chrysler ATF+4 (MS-9602) Fluid Capacity Transmission Fluid Capacity: Approx. 6.0 quarts (5.7 liters) for dry fill, 4.0 quarts (3.8 liters) for drain and refill. 📐 Dimensions Exterior Length: 194.6 inches Width: 77.5 inches Height: 68.5 inches Wheelbase: 119.2 inches Interior Passenger Volume: Approx. 150.5 cubic feet Cargo Cargo Volume Behind 3Rd Row: Approx. 38.1 cubic feet Cargo Volume With 3Rd Row Folded: Approx. 78.0 cubic feet Cargo Volume With 2Nd And 3Rd Rows Folded: Approx. 140.5 cubic feet Weights Curb Weight Min: Approx. 3900 lbs (2.4L engine) Curb Weight Max: Approx. 4200 lbs (3.8L engine) Gross Vehicle Weight Rating Gvwr: Approx. 5500-5800 lbs Towing Capacity: Up to 3500 lbs (with proper equipment and engine) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5 Stars (2004 Model Year) NHTSA Front Impact Passenger: 5 Stars (2004 Model Year) NHTSA Side Impact Front Driver: 4 Stars (2004 Model Year) NHTSA Side Impact Front Passenger: 4 Stars (2004 Model Year) NHTSA Side Impact Rear Driver: 4 Stars (2004 Model Year) NHTSA Side Impact Rear Passenger: 4 Stars (2004 Model Year) IIHS Frontal Offset: Good (2004 Model Year) Active Features ABS: Standard Traction Control: Optional (TCS) Passive Features Airbags Front: Standard driver and front passenger airbags. Airbags Side: Optional front-seat mounted side airbags. Seatbelts: Three-point seat belts...
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Chrysler Voyager 2004 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Voyager
Year:
2004
Codes
Platform Code:
RS
👋 Introduction
Market Position
Vehicle Segment:
Minivan
Target Audience:
Families, commercial use (taxi, shuttle services)
Competitive Analysis
Key Competitors:
Dodge Grand Caravan, Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture.
Key Features
Notable Features:
Spacious interior, versatile seating configurations, available Stow 'n Go seating (though not standard on all 2004 models, the platform supports it), power sliding doors, integrated rear entertainment systems (optional).
Manual Value Proposition:
Empowers owners and technicians with comprehensive, factory-accurate repair and maintenance information to ensure optimal performance and longevity.
📋 Manual Details
Coverage Areas
Markets Covered:
North America, Europe (specific variants)
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Systems:
2.4L DOHC I4, 3.3L OHV V6, 3.8L OHV V6: Engine mechanical, lubrication, cooling, fuel injection, ignition, emissions control, starting and charging, diagnosis and testing.
Transmission Systems:
4-speed automatic transmission (A604, A670): Service, overhaul, diagnosis, fluid types, shift control.
Drivetrain Systems:
Front-wheel drive, CV axles, differential: Inspection, replacement, service.
Suspension Systems:
Front strut suspension, rear torsion beam axle: Component identification, inspection, alignment specifications, shock absorber replacement, control arm service.
Steering Systems:
Power rack and pinion: Steering column, power steering pump, lines, rack and pinion unit service, troubleshooting.
Brake Systems:
Front disc brakes, rear drum brakes (some models rear disc): System components, hydraulic service, bleeding procedures, rotor and pad replacement, parking brake service.
Electrical Systems:
Battery, starting, charging, lighting, ignition, instruments, power windows, locks, mirrors, wipers, horn, HVAC controls, radio, power sliding doors, power liftgate: Wiring diagrams, component testing, troubleshooting.
Body And Chassis Systems:
Body panels, doors, hood, liftgate, interior trim, seating, frame and underbody: Repair procedures, panel replacement, rust prevention, body hardware.
HVAC Systems:
Air conditioning, heating, ventilation: Component service, refrigerant handling, leak detection, control module diagnosis.
Procedures Included
Diagnostic Procedures:
Troubleshooting guides based on symptoms, diagnostic trouble codes (DTCs), component testing procedures.
Maintenance Procedures:
Scheduled maintenance tasks, fluid changes, filter replacements, spark plug replacement, belt service, brake fluid flush.
Repair Procedures:
Step-by-step instructions for component removal, installation, and overhaul for all major vehicle systems.
Troubleshooting Guides:
Symptom-based diagnostic trees and component-specific testing.
Electrical Troubleshooting:
Detailed wiring diagrams, circuit descriptions, and component testing methods for all electrical systems.
Technical Depth
Depth:
Comprehensive, from basic fluid checks to complete engine and transmission overhauls.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
High-resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding Recommendation:
Print and spiral-bind for ease of use in a workshop environment.
Paper Type
Recommended Paper:
Durable, glossy paper for workshop conditions.
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
ECA
Engine Description 1:
2.4L (2429cc) DOHC 16-valve Inline-4 (World Engine)
Horsepower 1:
142 hp @ 5200 rpm
Torque 1:
158 lb-ft @ 4000 rpm
Optional Engine 1
Engine Code 2:
EGW
Engine Description 2:
3.3L (3301cc) OHV 12-valve V6
Horsepower 2:
180 hp @ 5000 rpm
Torque 2:
205 lb-ft @ 3200 rpm
Optional Engine 2
Engine Code 3:
EGQ
Engine Description 3:
3.8L (3778cc) OHV 12-valve V6
Horsepower 3:
197 hp @ 5200 rpm
Torque 3:
230 lb-ft @ 4000 rpm
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
Recommended Octane:
87 (minimum)
🔧 Transmission
Standard
Transmission Type Std:
4-speed automatic (A604/A670)
Optional
Transmission Type Opt:
Not applicable (standard across powertrain options)
Features
Transmission Features:
Driver-adaptive electronic controls, selectable gear range (AutoStick on some trims for 3.8L).
Fluid Specs
Transmission Fluid Type:
Chrysler ATF+4 (MS-9602)
Fluid Capacity
Transmission Fluid Capacity:
Approx. 6.0 quarts (5.7 liters) for dry fill, 4.0 quarts (3.8 liters) for drain and refill.
📐 Dimensions
Exterior
Length:
194.6 inches
Width:
77.5 inches
Height:
68.5 inches
Wheelbase:
119.2 inches
Interior
Passenger Volume:
Approx. 150.5 cubic feet
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 38.1 cubic feet
Cargo Volume With 3Rd Row Folded:
Approx. 78.0 cubic feet
Cargo Volume With 2Nd And 3Rd Rows Folded:
Approx. 140.5 cubic feet
Weights
Curb Weight Min:
Approx. 3900 lbs (2.4L engine)
Curb Weight Max:
Approx. 4200 lbs (3.8L engine)
Gross Vehicle Weight Rating Gvwr:
Approx. 5500-5800 lbs
Towing Capacity:
Up to 3500 lbs (with proper equipment and engine)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5 Stars (2004 Model Year)
NHTSA Front Impact Passenger:
5 Stars (2004 Model Year)
NHTSA Side Impact Front Driver:
4 Stars (2004 Model Year)
NHTSA Side Impact Front Passenger:
4 Stars (2004 Model Year)
NHTSA Side Impact Rear Driver:
4 Stars (2004 Model Year)
NHTSA Side Impact Rear Passenger:
4 Stars (2004 Model Year)
IIHS Frontal Offset:
Good (2004 Model Year)
Active Features
ABS:
Standard
Traction Control:
Optional (TCS)
Passive Features
Airbags Front:
Standard driver and front passenger airbags.
Airbags Side:
Optional front-seat mounted side airbags.
Seatbelts:
Three-point seat belts for all outboard seating positions, lap belts for center seats.
Child Seat Anchors:
LATCH system (Lower Anchors and Tethers for CHildren) in second row.
💡 Technology Features
Infotainment
Audio System:
Available AM/FM stereo with CD player, cassette player, and optional premium sound systems. Steering wheel mounted audio controls on some trims.
Rear Seat Entertainment:
Optional rear-seat video entertainment system with flip-down screen and wireless headphones available on higher trims.
Driver Assistance
Cruise Control:
Standard
Connectivity
Power Sliding Doors:
Available on most trims, operated by key fob, interior switch, or exterior handle. Manual override is essential for service.
Power Liftgate:
Optional, operated by key fob or interior switch.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for specifics).
Engine Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on inspection.
Spark Plug Replacement I4:
Every 100,000 miles (long-life spark plugs).
Spark Plug Replacement V6:
Every 30,000-100,000 miles depending on plug type (check manual).
Transmission Fluid Change:
Every 30,000-60,000 miles or as recommended in manual.
Coolant Flush:
Every 30,000-100,000 miles (check coolant type).
Fluid Specifications
Engine Oil Spec:
SAE 5W-30 (preferred), SAE 10W-30 or 10W-40 (acceptable in some climates). Check manual for exact specification based on engine and temperature.
Coolant Spec:
Chrysler HOAT (Hybrid Organic Acid Technology) antifreeze, typically orange or pink.
Brake Fluid Spec:
DOT 3
Power Steering Fluid Spec:
ATF+4 (MS-9602) or specific power steering fluid recommended by Chrysler.
Known Issues
Common Problems 1:
Transmission solenoid failures, intermittent power window/lock issues, front suspension wear (ball joints, tie rod ends), potential for coolant leaks (heater core, gaskets), EGR valve clogging (especially on V6 engines).
Common Problems 2:
Stuck automatic door locks, HVAC blower motor resistor failure, ABS sensor failures, exhaust system corrosion.
Preventative Measures:
Regular fluid checks and changes, timely replacement of worn suspension components, keeping fuel system clean, addressing coolant leaks promptly.
📚 Vehicle History
Brand Heritage
Parent Company:
Chrysler Corporation (later Fiat Chrysler Automobiles, now Stellantis)
Model Evolution
Generation:
Third Generation (1996-2007) - Often referred to as the RS platform.
Platform Sharing:
Shared platform with Dodge Caravan and Plymouth Voyager (though Plymouth brand was discontinued).
Production
Assembly Locations:
Windsor Assembly Plant, Windsor, Ontario, Canada; Saint Louis Assembly Plant, St. Louis, Missouri, USA (discontinued prior to 2004).
Production Years Model:
1984-2007 (Voyager nameplate has had various iterations globally, but this generation is key for 2004 model.
🏆 Awards & Recognition
Recognitions
Car And Driver Best Of:
While specific awards for the 2004 Voyager are less prominent than some competitors, its platform consistently received praise for practicality and affordability during its generation's run.
Ratings
Consumer Reports Reliability:
Variable across model years and specific components. The manual is crucial for addressing potential reliability concerns.
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