2004 Dodge Intrepid Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Intrepid Year: 2004 Vehicle Type: Full-size Sedan Codes Platform: Chrysler LH platform 👋 Introduction Market Position Market Position: The 2004 Dodge Intrepid was...

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Mots clés: 2004 Car Cars Dodge Intrepid

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Intrepid

Year:

Vehicle Type:

Full-size Sedan

Codes

Platform:

Chrysler LH platform

👋 Introduction

Market Position

Market Position:

The 2004 Dodge Intrepid was positioned as a large, front-wheel-drive sedan, often competing with other domestic and some import sedans in its class. It offered a blend of comfort, space, and performance, particularly with the larger V6 engine options.

Market Segment:

Large Sedan Segment

Competitive Analysis

Competitive Analysis:

Competed against vehicles like the Toyota Camry, Honda Accord, Ford Taurus, and Chevrolet Impala. The Intrepid aimed to provide a more aggressive styling and a slightly sportier feel compared to some competitors.

Key Features

Key Features Of Vehicle:

Distinctive styling, spacious interior, availability of potent V6 engines, and a relatively comfortable ride. Trim levels like the ES and SXT offered different levels of luxury and sportiness.

📋 Manual Details

Coverage Areas

Coverage Areas:

• Lubrication & Maintenance

• Suspension

• Driveline

• Brakes

• Cooling System

• Audio/Video Systems

• Chime/Buzzer Systems

• Clock

• Electronic Control Modules

• Engine Systems

• Heated Systems

• Horn

• Ignition Control

• Instrument Cluster

• Lamps

• Message Systems

• Power Systems

• Restraints (Airbags)

• Speed Control (Cruise Control)

• Vehicle Theft Security System

• Wipers/Washers

• Wiring Diagrams

• Engine Mechanical

• Exhaust System

• Frame & Bumpers

• Fuel System

• Steering

• Transaxle (Automatic Transmission)

• Tires/Wheels

• Body (Interior & Exterior)

• Heating & Air Conditioning (HVAC)

• Emissions Control

Page Count

Estimated Page Count:

Over 2000 pages (typical for factory service manuals of this era)

Manual Type

Manual Type:

Factory Service Repair Manual

Content Type:

Diagnostic, Repair, and Maintenance Manual

Language

Language:

English

Format

Format:

Digital Download (Zip/PDF)

📖 Manual Coverage

Systems Covered

Systems Covered:

• Engine (all variants)

• Transmission (automatic transaxle)

• Braking System (ABS, standard)

• Suspension (front and rear)

• Steering System

• Fuel System (delivery, injection)

• Cooling System

• Exhaust System

• Electrical System (charging, starting, lighting, accessories)

• Ignition System

• HVAC System

• Body Control Modules

• Safety Systems (SRS/Airbag, seatbelts)

• Security System

• Instrument Cluster and Gauges

• Power Accessory Systems (windows, locks, mirrors)

• Audio/Video Components

• Emissions Control Systems

• Driveline Components

• Wheel and Tire Systems

Electrical Systems Details:

Extensive coverage of the vehicle's electrical system, including detailed wiring diagrams for all circuits, power distribution, lighting, ignition, fuel injection, body control modules, comfort systems, and diagnostic connectors.

Body And Frame Coverage:

Includes procedures for body panel alignment, bumper repair, door and window mechanisms, interior trim removal and installation, and frame inspection and repair.

Procedures Included

Procedures Included:

• Routine Maintenance

• Scheduled Maintenance

• Diagnostic Procedures

• Troubleshooting Guides

• Component Removal and Installation

• Repair Procedures

• Wiring Harness Repair

• Torque Specifications

• Fluid Capacities and Specifications

• Component Adjustment

• System Bleeding (Brakes, Cooling)

• Component Testing

• Reassembly Procedures

Engine Repair Procedures:

Covers engine assembly/disassembly, cylinder head removal/installation, piston and connecting rod service, crankshaft and bearing inspection, camshaft timing, valve train service, and detailed diagnostic procedures for all engine control systems.

Transmission Repair Procedures:

Includes overhaul procedures for the automatic transaxle, including torque converter replacement, clutch pack service, valve body diagnosis and repair, hydraulic system testing, and shift control system calibration.

Brake System Procedures:

Detailed steps for brake pad and rotor replacement, caliper service, brake line inspection and replacement, ABS component testing and diagnosis, and brake system bleeding.

Suspension Steering Procedures:

Instructions for inspecting and replacing front and rear suspension components (struts, shocks, control arms, ball joints, bushings), wheel bearing replacement, and steering system service (tie rod ends, power steering pump, steering rack).

HVAC System Procedures:

Guidance on air conditioning system service, refrigerant handling, compressor replacement, evaporator and condenser service, blower motor replacement, and heater core replacement. Also includes climate control system diagnostics.

Exhaust System Procedures:

Covers exhaust system component replacement (catalytic converter, mufflers, pipes), hanger inspection, and leak detection.

Technical Depth

Technical Depth:

Comprehensive: Covers everything from basic fluid checks and filter replacements to in-depth engine and transmission overhauls, electrical system diagnostics, and body repair. Includes detailed diagrams, schematics, and step-by-step instructions suitable for professional technicians and advanced DIY enthusiasts.

Diagnostic Capabilities:

Includes diagnostic trouble codes (DTCs), symptom-based troubleshooting charts, component testing procedures, and specifications for using diagnostic scan tools.

📊 Manual Specifications

File Format

File Format Details:

Provided as a compressed Zip archive containing PDF files. PDFs are typically searchable and can be printed. Quality may vary depending on the source digitization, but factory manuals are generally high-resolution.

PDF Features:

PDF files often contain bookmarks for easy navigation and may have embedded hyperlinks for cross-referencing within the manual. Text is usually selectable for copy-paste functions or search.

Print Quality

Print Quality Consideration:

Digital format allows for high-resolution printing of individual pages or sections. Actual print quality depends on the user's printer and paper.

Binding Type

Binding Type:

N/A (Digital download format)

Paper Type

Paper Type:

N/A (Digital download format)

Completeness

Manual Completeness:

This factory service manual is designed to be a complete guide for the specified vehicle, covering all major systems and components for diagnosis, repair, and maintenance.

⚙️ Engine Specifications

Primary Engine

Engine Options:

• 2.7L Magnum V6 (135 hp, 171 lb-ft torque)

• 3.2L Magnum V6 (200 hp, 215 lb-ft torque) - Primarily on SXT and ES trims

• 3.5L High Output Magnum V6 (234 hp, 241 lb-ft torque) - Primarily on ES trims

Engine Code Examples:

2.7L (EER), 3.2L (EGJ), 3.5L HO (EVS)

Engine Design:

Magnum V6 family (overhead valve, pushrod design for 2.7L and 3.2L, overhead cam for 3.5L HO)

Performance

Performance Highlights:

The 3.5L HO V6 provided brisk acceleration and was the performance benchmark for the Intrepid. The 2.7L was the entry-level option focusing on fuel economy.

Fuel System

Fuel System Type:

Sequential Multi-Port Fuel Injection (MPI)

🔧 Transmission

Standard

Standard Transmission:

4-speed automatic transaxle (41TE/42LE variants)

Optional

Optional Transmission:

N/A (Only automatic transmission was offered)

Features

Transmission Features:

Includes features like electronically controlled shifting, torque converter lock-up for improved efficiency, and adaptive shift logic.

📐 Dimensions

Exterior

Exterior Dimensions:

Length: Approx. 203.7 inches, Width: Approx. 74.4 inches, Height: Approx. 56.9 inches, Wheelbase: Approx. 113.0 inches

Interior

Interior Dimensions:

Front Headroom: Approx. 39.5 in, Front Legroom: Approx. 42.3 in, Rear Headroom: Approx. 37.7 in, Rear Legroom: Approx. 37.4 in

Cargo

Cargo Volume:

Trunk Capacity: Approx. 16.1 cubic feet

Weights

Curb Weight:

Approx. 3500-3700 lbs, depending on engine and trim level.

🛡️ Safety Features

Ratings

NHTSA Safety Ratings:

Varies by specific model and testing year, but generally aimed for good frontal and side impact protection for its era. Check specific recall data and NHTSA reports for detailed ratings.

Active Features

Active Safety Features:

• Four-wheel Anti-lock Braking System (ABS)

• Traction Control (on some higher trims or optional)

Passive Features

Passive Safety Features:

• Driver and front passenger airbags

• Side-impact airbags (optional on some trims)

• Front and rear crumple zones

• Reinforced body structure

Seatbelt Pretensioners:

Equipped with seatbelt pretensioners for enhanced occupant protection.

💡 Technology Features

Infotainment

Infotainment System:

Base models featured an AM/FM stereo with CD player. Higher trims offered premium audio systems, CD changers, and cassette players. Optional Infinity audio systems were available.

Driver Assistance

Driver Assistance Features:

• Speed Control (Cruise Control)

• Optional ABS and Traction Control

Connectivity

Connectivity Options:

Limited by modern standards. Primarily focused on audio connectivity. Some models may have had optional steering wheel audio controls.

🔧 Maintenance

Service Intervals

Recommended Service Intervals:

Typical intervals for 2004 models: Oil Change: Every 3,000-7,500 miles (depending on oil type and driving conditions, consult manual), Air Filter: Every 30,000 miles, Spark Plugs: Every 60,000-100,000 miles (depending on plug type), Transmission Fluid: Every 30,000-60,000 miles, Coolant: Every 30,000-100,000 miles (depending on type).

Brake Fluid Change Interval:

Every 24 months or 30,000 miles (recommended)

Drive Belt Inspection Interval:

Inspect every 30,000 miles, replace as needed.

Fluid Specifications

Key Fluid Specifications:

{'engine_oil': "API SN or higher, SAE 5W-30 (check owner's manual for specific viscosity and capacity)", 'transmission_fluid': 'ATF+4 (Mopar P/N 05013457AA or equivalent)', 'coolant': "Chrysler's HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, 50/50 mix with distilled water", 'brake_fluid': 'DOT 3', 'power_steering_fluid': 'Chrysler Power Steering Fluid (Mopar P/N 04398833AA or equivalent)'}

Engine Oil Part Number Example:

Mopar 68157995AA 5W-30 (for modern equivalent, original might differ)

Transmission Fluid Part Number Example:

Mopar 68218057AB ATF+4

Coolant Part Number Example:

Mopar 68048553AA (50/50 pre-diluted) or equivalent HOAT antifreeze

Known Issues

Common Issues:

• Transmission problems (slipping, rough shifting, especially in earlier models)

• Cooling system leaks (radiator, water pump, hoses)

• Power steering pump noise or leaks

• Oil leaks (valve cover gaskets, oil pan gasket)

• Alternator failure

• Wheel bearing wear

• CV joint wear

• Heater core leaks/clogs

• Ignition coil issues

• Electronic throttle control issues (on later models with this technology)

📚 Vehicle History

Brand Heritage

Dodge Heritage:

Dodge, as a division of Chrysler, has a long history of producing a wide range of vehicles, from performance muscle cars to practical family cars and minivans. The Intrepid represents Dodge's effort in the large sedan market.

Model Evolution

Intrepid Evolution:

The 2004 model year represents the latter part of the second generation of the Dodge Intrepid (1998-2004). This generation was based on the Chrysler LH platform and saw styling updates and powertrain refinements over its lifespan. The 2004 model year received minor updates, continuing the established design and mechanicals.

Generation Designation:

Second Generation (1998-2004)

Production

Production Location:

The Dodge Intrepid was primarily manufactured at the Brampton Assembly plant in Ontario, Canada.