2004 Chrysler Town & Country Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Town & Country Year: 2004 Codes Chassis Code: RS 👋 Introduction Market Position Segment: Full-size Minivan / Family Van Competitive Analysis Key Competitors 2004: Honda Odyssey, Toyota Sienna, Ford Freestar, Mercury Monterey, Kia Sedona, Mazda MPV Key Features Target Audience: Families, individuals requiring flexible cargo and passenger space, DIY mechanics Unique Selling Points: Versatile Stow 'n Go seating (available on some trims), comfortable ride, ample interior space, practical features for family use. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive Maintenance, Troubleshooting, and Repair Page Count Estimated Pages: Over 1500 Manual Type Type: Factory Certified Repair Manual / Service Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Exhaust System, Transmission (Automatic) Chassis: Suspension (Front & Rear), Steering System, Brake System (Front & Rear Disc), Wheels & Tires Electrical: Battery, Charging System, Starting System, Ignition System, Lighting, Instrumentation, Body Controls, HVAC Controls, Power Accessories (Windows, Doors, Seats) Body: Exterior Body Panels, Interior Trim, Doors, Liftgate, Seats, Glass, Seals Procedures Included Maintenance: Scheduled Maintenance, Fluid Changes (Engine Oil, Coolant, Transmission Fluid, Brake Fluid, Power Steering Fluid), Filter Replacements (Oil, Air, Cabin, Fuel), Spark Plug Replacement, Belt Replacement Troubleshooting: Diagnostic Trouble Codes (DTCs), Symptom-Based Troubleshooting, Electrical System Diagnostics, Engine Performance Issues, Transmission Shifting Problems Repair: Engine Component Overhaul (Head Gaskets, Seals, Pulleys), Transmission Service and Overhaul, Brake System Repairs (Calipers, Rotors, Lines), Suspension Component Replacement (Struts, Ball Joints, Bushings), Steering Component Repair (Tie Rods, Rack and Pinion), Electrical Component Replacement (Sensors, Actuators, Modules), HVAC System Repairs, Body Panel Repair and Replacement Technical Depth Depth: Detailed step-by-step repair procedures, torque specifications, diagnostic flowcharts, wiring diagrams, exploded views, special tool requirements, and specifications for all major components and systems. 📊 Manual Specifications File Format File Type: PDF Print Quality Resolution: High-resolution, suitable for printing individual pages or the entire manual. Clear diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: EDZ Engine Type: 3.3L (3301cc) V6 SOHC 12-Valve Bore X Stroke: 3.58 in x 3.27 in (91 mm x 83 mm) Compression Ratio: 9.3:1 Horsepower: 180 hp @ 5000 rpm Torque: 210 lb-ft @ 3500 rpm Optional Engine Engine Code: EGA Engine Type: 3.8L (3778cc) V6 OHV 12-Valve Bore X Stroke: 3.91 in x 3.37 in (99 mm x 85.5 mm) Compression Ratio: 9.1:1 Horsepower: 200 hp @ 5000 rpm Torque: 230 lb-ft @ 3200 rpm Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 Octane Recommended) Engine Controls ECU: Chrysler NGC (Next Generation Controller) or equivalent 🔧 Transmission Standard Transmission Type: 4-Speed Automatic Transaxle Transmission Model 3.3L: 40TE / 41TE Transmission Model 3.8L: 42LE Optional Optional Transmission: N/A (All models feature 4-speed automatic) Features Torque Converter Lockup: Electronically controlled Fluid Type Recommended Fluid: ATF+4 (Automatic Transmission Fluid Type 9602 or equivalent) Fluid Capacity Capacity: Approx. 7.5 quarts (7.1 liters) for dry fill, 4.5 quarts (4.3 liters) for fluid change. 📐 Dimensions Exterior Length: 201.0 inches (5105 mm) Width: 77.1 inches (1958 mm) Height: 68.0 inches (1727 mm) Wheelbase: 124.2 inches (3155 mm) Interior Passenger Volume: Approx. 155 cubic feet Cargo Cargo Volume Behind 3Rd Row: Approx. 25.0 cubic feet Cargo Volume With 3Rd Row Folded: Approx. 95.0 cubic feet Cargo Volume With 2Nd And 3Rd Rows Folded: Approx. 140.0 cubic feet Weights Curb Weight 3.3L: Approx. 4300 - 4500 lbs (1950 - 2041 kg) Curb Weight 3.8L: Approx. 4400 - 4600 lbs (1996 - 2087 kg) Gross Vehicle Weight Rating Gvwr: Approx. 5700 - 5900 lbs (2585 - 2676 kg) 🛡️ Safety Features Ratings NHTSA Frontal Crash Test Driver: 5 Stars (when equipped with advanced airbags) NHTSA Frontal Crash Test Passenger: 5 Stars (when equipped with advanced airbags) NHTSA Side Impact Crash Test Front Seat: 5 Stars NHTSA Side Impact Crash Test Rear Seat: 5 Stars IIHS Frontal Offset Score: Good IIHS Side Impact Score: Good Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional Traction Control System (TCS) Electronic Stability: Optional Electronic Stability Program (ESP) - marketed as 'Roll Sense' or similar Passive Features Airbags: Driver and front passenger airbags (optional advanced multi-stage airbags), optional side curtain airbags for all rows. Seatbelts: 3-point seatbelts in all seating positions, LATCH child seat anchor system. 💡 Technology Features Infotainment Audio System: Available AM/FM stereo with CD player, optional CD/DVD changer, rear-seat entertainment system. Navigation: Optional factory navigation system available on higher trims. Driver Assistance Parking Assistance: Optional rear parking assist sensors. Connectivity Remote Entry: Standard keyless entry with remote fob. Remote Start: Optional factory remote start system. 🔧 Maintenance Service Intervals Engine Oil Change: Every 3,750 miles (6,000 km) or 3 months (severe service) / Every 7,500 miles (12,000 km) or 6 months (normal service), using synthetic blend...

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Description

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Town & Country

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Full-size Minivan / Family Van

Competitive Analysis

Key Competitors 2004:

Honda Odyssey, Toyota Sienna, Ford Freestar, Mercury Monterey, Kia Sedona, Mazda MPV

Key Features

Target Audience:

Families, individuals requiring flexible cargo and passenger space, DIY mechanics

Unique Selling Points:

Versatile Stow 'n Go seating (available on some trims), comfortable ride, ample interior space, practical features for family use.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive Maintenance, Troubleshooting, and Repair

Page Count

Estimated Pages:

Over 1500

Manual Type

Type:

Factory Certified Repair Manual / Service Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Fuel System, Exhaust System, Transmission (Automatic)

Chassis:

Suspension (Front & Rear), Steering System, Brake System (Front & Rear Disc), Wheels & Tires

Electrical:

Battery, Charging System, Starting System, Ignition System, Lighting, Instrumentation, Body Controls, HVAC Controls, Power Accessories (Windows, Doors, Seats)

Body:

Exterior Body Panels, Interior Trim, Doors, Liftgate, Seats, Glass, Seals

Procedures Included

Maintenance:

Scheduled Maintenance, Fluid Changes (Engine Oil, Coolant, Transmission Fluid, Brake Fluid, Power Steering Fluid), Filter Replacements (Oil, Air, Cabin, Fuel), Spark Plug Replacement, Belt Replacement

Troubleshooting:

Diagnostic Trouble Codes (DTCs), Symptom-Based Troubleshooting, Electrical System Diagnostics, Engine Performance Issues, Transmission Shifting Problems

Repair:

Engine Component Overhaul (Head Gaskets, Seals, Pulleys), Transmission Service and Overhaul, Brake System Repairs (Calipers, Rotors, Lines), Suspension Component Replacement (Struts, Ball Joints, Bushings), Steering Component Repair (Tie Rods, Rack and Pinion), Electrical Component Replacement (Sensors, Actuators, Modules), HVAC System Repairs, Body Panel Repair and Replacement

Technical Depth

Depth:

Detailed step-by-step repair procedures, torque specifications, diagnostic flowcharts, wiring diagrams, exploded views, special tool requirements, and specifications for all major components and systems.

📊 Manual Specifications

File Format

File Type:

Print Quality

Resolution:

High-resolution, suitable for printing individual pages or the entire manual. Clear diagrams and text.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Engine Type:

3.3L (3301cc) V6 SOHC 12-Valve

Bore X Stroke:

3.58 in x 3.27 in (91 mm x 83 mm)

Compression Ratio:

9.3:1

Horsepower:

180 hp @ 5000 rpm

Torque:

210 lb-ft @ 3500 rpm

Optional Engine

Engine Code:

Engine Type:

3.8L (3778cc) V6 OHV 12-Valve

Bore X Stroke:

3.91 in x 3.37 in (99 mm x 85.5 mm)

Compression Ratio:

9.1:1

Horsepower:

200 hp @ 5000 rpm

Torque:

230 lb-ft @ 3200 rpm

Fuel System

Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 Octane Recommended)

Engine Controls

Chrysler NGC (Next Generation Controller) or equivalent

🔧 Transmission

Standard

Transmission Type:

4-Speed Automatic Transaxle

Transmission Model 3.3L:

40TE / 41TE

Transmission Model 3.8L:

Optional

Optional Transmission:

N/A (All models feature 4-speed automatic)

Features

Torque Converter Lockup:

Electronically controlled

Fluid Type

Recommended Fluid:

ATF+4 (Automatic Transmission Fluid Type 9602 or equivalent)

Fluid Capacity

Capacity:

Approx. 7.5 quarts (7.1 liters) for dry fill, 4.5 quarts (4.3 liters) for fluid change.

📐 Dimensions

Exterior

Length:

201.0 inches (5105 mm)

Width:

77.1 inches (1958 mm)

Height:

68.0 inches (1727 mm)

Wheelbase:

124.2 inches (3155 mm)

Interior

Passenger Volume:

Approx. 155 cubic feet

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 25.0 cubic feet

Cargo Volume With 3Rd Row Folded:

Approx. 95.0 cubic feet

Cargo Volume With 2Nd And 3Rd Rows Folded:

Approx. 140.0 cubic feet

Weights

Curb Weight 3.3L:

Approx. 4300 - 4500 lbs (1950 - 2041 kg)

Curb Weight 3.8L:

Approx. 4400 - 4600 lbs (1996 - 2087 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 5700 - 5900 lbs (2585 - 2676 kg)

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Test Driver:

5 Stars (when equipped with advanced airbags)

NHTSA Frontal Crash Test Passenger:

5 Stars (when equipped with advanced airbags)

NHTSA Side Impact Crash Test Front Seat:

5 Stars

NHTSA Side Impact Crash Test Rear Seat:

5 Stars

IIHS Frontal Offset Score:

IIHS Side Impact Score:

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System (TCS)

Electronic Stability:

Optional Electronic Stability Program (ESP) - marketed as 'Roll Sense' or similar

Passive Features

Airbags:

Driver and front passenger airbags (optional advanced multi-stage airbags), optional side curtain airbags for all rows.

Seatbelts:

3-point seatbelts in all seating positions, LATCH child seat anchor system.

💡 Technology Features

Infotainment

Audio System:

Available AM/FM stereo with CD player, optional CD/DVD changer, rear-seat entertainment system.

Navigation:

Optional factory navigation system available on higher trims.

Driver Assistance

Parking Assistance:

Optional rear parking assist sensors.

Connectivity

Remote Entry:

Standard keyless entry with remote fob.

Remote Start:

Optional factory remote start system.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,750 miles (6,000 km) or 3 months (severe service) / Every 7,500 miles (12,000 km) or 6 months (normal service), using synthetic blend or full synthetic oil. Check manual for specific recommendation based on oil type used.

Engine Air Filter:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Cabin Air Filter:

Inspect/replace every 15,000 miles (24,000 km) or annually.

Transmission Fluid Change:

Inspect every 30,000 miles (48,000 km), change every 60,000 - 100,000 miles (96,000 - 160,000 km) depending on service and fluid type (ATF+4 is generally long-life).

Spark Plugs 3.3L:

Platinum or Iridium (OEM recommended), typically 100,000 mile interval.

Spark Plugs 3.8L:

Platinum or Iridium (OEM recommended), typically 100,000 mile interval.

Coolant Flush:

First change at 100,000 miles (160,000 km), then every 50,000 miles (80,000 km) thereafter. Use Mopar HOAT (Hybrid Organic Acid Technology) or equivalent.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (API Certified)

Engine Oil Capacity 3.3L:

Approx. 4.5 quarts (4.3 liters) with filter change.

Engine Oil Capacity 3.8L:

Approx. 5.0 quarts (4.7 liters) with filter change.

Coolant Type:

Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant (Orange)

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

ATF+4 (Automatic Transmission Fluid Type 9602 or equivalent)

Known Issues

Common Issues Engine:

Intake manifold gasket leaks, oil filter adapter leaks, occasional spark plug thread issues (Helicoil repair may be needed), PCV valve failure.

Common Issues Transmission:

Torque converter shudder, potential for transmission solenoid issues (less common with ATF+4), bearing failures if fluid levels are not maintained.

Common Issues Suspension:

Worn sway bar links and bushings, premature front strut wear, tie rod end wear.

Common Issues Electrical:

Power window motor failures, HVAC blower motor resistor failure, ABS sensor failures, intermittent door lock actuator issues.

Common Issues Body:

Power sliding door mechanism issues, liftgate actuator wear, rear wiper motor failure, body rust in certain climates.

📚 Vehicle History

Brand Heritage

Chrysler Minivan Legacy:

Chrysler pioneered the minivan segment with the original Dodge Caravan and Plymouth Voyager in 1983, establishing the segment's core appeal.

Model Evolution

Generation:

Third Generation (1996-2000) - This 2004 model is part of the fourth generation, which debuted for the 2001 model year and received a significant facelift for 2005.

Platform:

Chrysler RS platform

Production

Assembly Locations:

Windsor, Ontario, Canada; St. Louis, Missouri, USA (for specific model years/trims)

Production Years For This Generation:

2001-2007

🏆 Awards & Recognition

Recognitions

Previous Awards Model Line:

While specific awards for the 2004 model year are less documented, the Town & Country consistently ranked well for practicality and family-friendliness within its segment during its generation. Chrysler minivans have a long history of industry accolades for innovation and value.