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DODGE INTREPID 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Intrepid Year: 2004 Codes Platform Code: LH 👋 Introduction Market Position Segment: Full-size Sedan Key Selling Points Model: Spacious interior, distinctive styling, comfortable ride, powerful V6 engines. Competitive Analysis Direct Competitors 2004: Ford Crown Victoria, Chevrolet Impala, Toyota Avalon, Buick LeSabre. Key Features Manual Value Proposition: Provides factory-level diagnostic and repair information, empowering owners and independent mechanics. 📋 Manual Details Coverage Areas Coverage Summary: Comprehensive service and repair procedures for the 2004 Dodge Intrepid. Page Count Estimated Pages: 2000+ Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, overhaul, cylinder head, block, crankshaft, pistons, timing. Engine Electrical: Ignition system, starting system, charging system, fuel injection, sensors, ECU diagnostics. Transmission: Automatic transmission (42LE) disassembly, assembly, repair, torque converter, valve body. Brakes: Hydraulic system, ABS, disc brakes (front/rear), parking brake, bleeding procedures. Suspension: Front suspension (struts, control arms), rear suspension (independent), alignment specifications. Steering: Power steering system, steering column, rack and pinion. HVAC: Air conditioning system, heater core, blower motor, climate control operation. Electrical Body: Lighting, wipers, horn, power windows, power locks, interior/exterior trim. Chassis Electrical: Instrument cluster, wiring diagrams, fuses, relays, diagnostics. Exhaust System: Exhaust manifold, catalytic converter, mufflers, pipes. Fuel System: Fuel tank, fuel pump, fuel lines, fuel filter, injectors. Cooling System: Radiator, water pump, thermostat, coolant, hoses, fan. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement. Troubleshooting: Diagnostic procedures for common faults and symptoms, diagnostic trouble codes (DTCs). Component Repair: Detailed step-by-step repair instructions for all major components. Rebuilds: Complete engine and transmission overhaul procedures. Diagnostics Tools: Use of scan tools, multimeters, and specialized equipment. Wiring Diagrams: Detailed electrical circuit diagrams for all vehicle systems. Specifications: Torque specifications, clearances, measurements, and tolerances. Body Repair: Panel replacement, collision repair guidance, trim removal/installation. Technical Depth Depth Level: Comprehensive - from basic maintenance to complete engine/transmission rebuilds. Diagnostic Detail: In-depth diagnostics with symptom-based troubleshooting charts and DTC explanations. Diagrams Illustrations: Includes detailed illustrations, diagrams, and exploded views. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick information retrieval. Print Quality Resolution: High-resolution for clear viewing of diagrams and text. Printability: Printable pages for hands-on use. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: EGW Engine Type: 3.5L V6 SOHC (215 cu. in.) Bore X Stroke: 3.54 in. x 3.73 in. (90 mm x 94.5 mm) Displacement: 3.5 Liters (3497 cc) Compression Ratio: 9.0:1 Horsepower: 234 hp @ 5800 rpm Torque: 241 lb-ft @ 4000 rpm Optional Engine Engine Code: AJA Engine Type: 2.7L V6 DOHC (167 cu. in.) - Less Common Horsepower: 200 hp @ 6000 rpm Torque: 192 lb-ft @ 4000 rpm Fuel System Fuel Delivery: Sequential Electronic Fuel Injection (SEFI) Fuel Type: Unleaded gasoline, 87 octane recommended Fuel Pressure: 39 psi (265 kPa) Performance 0-60 Mph Approx: 7.5 - 8.5 seconds 🔧 Transmission Standard Transmission Type: 4-Speed Automatic Transmission Code: 42LE Features Transmission Features: AutoStick manual shifting capability (on some trims) Fluid Specifications Transmission Fluid Type: ATF+4 (Mopar) Fluid Capacities Transmission Fluid Capacity: 7.0 US quarts (6.6 Liters) 📐 Dimensions Exterior Length: 200.0 inches (5080 mm) Width: 74.4 inches (1890 mm) Height: 56.7 inches (1440 mm) Wheelbase: 113.0 inches (2870 mm) Front Track: 62.4 inches (1585 mm) Rear Track: 61.8 inches (1570 mm) Weights Curb Weight: 3599 - 3767 lbs (1632 - 1709 kg) Gross Vehicle Weight Rating: 4650 lbs (2109 kg) Cargo Trunk Volume: 16.1 cu ft (456 Liters) 🛡️ Safety Features Ratings NHTSA Frontal Driver Impact: Good (2004 Model Year Data) NHTSA Frontal Passenger Impact: Good (2004 Model Year Data) IIHS Frontal Offset Score: Good (for 2002-2004 models) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Available Traction Control System (TCS) Passive Features Airbags Front: Standard Driver and Front Passenger Airbags Airbags Side: Available Front Side-Impact Airbags Seatbelts: 3-point height-adjustable front seat belts with pretensioners, rear 3-point seat belts. 💡 Technology Features Infotainment Audio System: Optional Infinity sound systems, cassette and CD players. Climate Control: Manual and optional automatic climate control systems. Driver Assistance Cruise Control: Standard cruise control. Connectivity Connectivity Options: Limited to optional cassette/CD players and analog radio. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6 months, whichever comes first. Air Filter Replacement: Every 30,000 miles (48,000 km) or as needed based on driving conditions. Spark Plug Replacement: Every 100,000 miles (160,000 km) for platinum-tipped plugs. Coolant Flush: Every 100,000 miles (160,000 km) or 5 years. Fluid Specifications Engine Oil Type: SAE 5W-30 Synthetic (preferred for cooler climates) or SAE 10W-30 Conventional. Engine Oil Capacity: 4.5 US quarts (4.3 Liters) with filter change. Coolant Type: Chrysler...
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DODGE INTREPID 2004 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Intrepid
Year:
2004
Codes
Platform Code:
LH
👋 Introduction
Market Position
Segment:
Full-size Sedan
Key Selling Points Model:
Spacious interior, distinctive styling, comfortable ride, powerful V6 engines.
Competitive Analysis
Direct Competitors 2004:
Ford Crown Victoria, Chevrolet Impala, Toyota Avalon, Buick LeSabre.
Key Features
Manual Value Proposition:
Provides factory-level diagnostic and repair information, empowering owners and independent mechanics.
📋 Manual Details
Coverage Areas
Coverage Summary:
Comprehensive service and repair procedures for the 2004 Dodge Intrepid.
Page Count
Estimated Pages:
2000+
Manual Type
Manual Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine disassembly, assembly, overhaul, cylinder head, block, crankshaft, pistons, timing.
Engine Electrical:
Ignition system, starting system, charging system, fuel injection, sensors, ECU diagnostics.
Transmission:
Automatic transmission (42LE) disassembly, assembly, repair, torque converter, valve body.
Brakes:
Hydraulic system, ABS, disc brakes (front/rear), parking brake, bleeding procedures.
Suspension:
Front suspension (struts, control arms), rear suspension (independent), alignment specifications.
Steering:
Power steering system, steering column, rack and pinion.
HVAC:
Air conditioning system, heater core, blower motor, climate control operation.
Electrical Body:
Lighting, wipers, horn, power windows, power locks, interior/exterior trim.
Chassis Electrical:
Instrument cluster, wiring diagrams, fuses, relays, diagnostics.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, pipes.
Fuel System:
Fuel tank, fuel pump, fuel lines, fuel filter, injectors.
Cooling System:
Radiator, water pump, thermostat, coolant, hoses, fan.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement.
Troubleshooting:
Diagnostic procedures for common faults and symptoms, diagnostic trouble codes (DTCs).
Component Repair:
Detailed step-by-step repair instructions for all major components.
Rebuilds:
Complete engine and transmission overhaul procedures.
Diagnostics Tools:
Use of scan tools, multimeters, and specialized equipment.
Wiring Diagrams:
Detailed electrical circuit diagrams for all vehicle systems.
Specifications:
Torque specifications, clearances, measurements, and tolerances.
Body Repair:
Panel replacement, collision repair guidance, trim removal/installation.
Technical Depth
Depth Level:
Comprehensive - from basic maintenance to complete engine/transmission rebuilds.
Diagnostic Detail:
In-depth diagnostics with symptom-based troubleshooting charts and DTC explanations.
Diagrams Illustrations:
Includes detailed illustrations, diagrams, and exploded views.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text for quick information retrieval.
Print Quality
Resolution:
High-resolution for clear viewing of diagrams and text.
Printability:
Printable pages for hands-on use.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
EGW
Engine Type:
3.5L V6 SOHC (215 cu. in.)
Bore X Stroke:
3.54 in. x 3.73 in. (90 mm x 94.5 mm)
Displacement:
3.5 Liters (3497 cc)
Compression Ratio:
9.0:1
Horsepower:
234 hp @ 5800 rpm
Torque:
241 lb-ft @ 4000 rpm
Optional Engine
Engine Code:
AJA
Engine Type:
2.7L V6 DOHC (167 cu. in.) - Less Common
Horsepower:
200 hp @ 6000 rpm
Torque:
192 lb-ft @ 4000 rpm
Fuel System
Fuel Delivery:
Sequential Electronic Fuel Injection (SEFI)
Fuel Type:
Unleaded gasoline, 87 octane recommended
Fuel Pressure:
39 psi (265 kPa)
Performance
0-60 Mph Approx:
7.5 - 8.5 seconds
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic
Transmission Code:
42LE
Features
Transmission Features:
AutoStick manual shifting capability (on some trims)
Fluid Specifications
Transmission Fluid Type:
ATF+4 (Mopar)
Fluid Capacities
Transmission Fluid Capacity:
7.0 US quarts (6.6 Liters)
📐 Dimensions
Exterior
Length:
200.0 inches (5080 mm)
Width:
74.4 inches (1890 mm)
Height:
56.7 inches (1440 mm)
Wheelbase:
113.0 inches (2870 mm)
Front Track:
62.4 inches (1585 mm)
Rear Track:
61.8 inches (1570 mm)
Weights
Curb Weight:
3599 - 3767 lbs (1632 - 1709 kg)
Gross Vehicle Weight Rating:
4650 lbs (2109 kg)
Cargo
Trunk Volume:
16.1 cu ft (456 Liters)
🛡️ Safety Features
Ratings
NHTSA Frontal Driver Impact:
Good (2004 Model Year Data)
NHTSA Frontal Passenger Impact:
Good (2004 Model Year Data)
IIHS Frontal Offset Score:
Good (for 2002-2004 models)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS)
Passive Features
Airbags Front:
Standard Driver and Front Passenger Airbags
Airbags Side:
Available Front Side-Impact Airbags
Seatbelts:
3-point height-adjustable front seat belts with pretensioners, rear 3-point seat belts.
💡 Technology Features
Infotainment
Audio System:
Optional Infinity sound systems, cassette and CD players.
Climate Control:
Manual and optional automatic climate control systems.
Driver Assistance
Cruise Control:
Standard cruise control.
Connectivity
Connectivity Options:
Limited to optional cassette/CD players and analog radio.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6 months, whichever comes first.
Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed based on driving conditions.
Spark Plug Replacement:
Every 100,000 miles (160,000 km) for platinum-tipped plugs.
Coolant Flush:
Every 100,000 miles (160,000 km) or 5 years.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 Synthetic (preferred for cooler climates) or SAE 10W-30 Conventional.
Engine Oil Capacity:
4.5 US quarts (4.3 Liters) with filter change.
Coolant Type:
Chrysler Type III (HOAT) Antifreeze/Coolant, 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3
Power Steering Fluid:
ATF+4 (Mopar)
Known Issues
Common Problems Model:
Interior water leaks (door seals, sunroof drains), suspension component wear (ball joints, tie rods), power steering pump leaks, PCV valve issues, transmission solenoid issues.
Manual Utility Known Issues:
The manual will provide diagnostic procedures to identify and repair these common issues.
📚 Vehicle History
Brand Heritage
Brand History Context:
Dodge, a division of Chrysler, has a long history of producing American muscle cars and family vehicles.
Model Evolution
Generation:
Second Generation (1998-2004)
Design Philosophy:
Distinctive cab-forward design, influenced by aerodynamic principles, aimed to maximize interior space.
Production
Production Years Model:
1993-2004
Assembly Location:
Sterling Heights Assembly Plant, Sterling Heights, Michigan
🏆 Awards & Recognition
Recognitions
Model Awards:
While specific awards for the 2004 model are not prominent, the LH platform generally received praise for its interior space and comfort in reviews of its era.
Ratings
Consumer Reviews:
Mixed, often citing good value and space but also reliability concerns in later years.
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