🏷️ Basic Information

Make:

Chrysler

Model:

Voyager

Year:

2004

Platform Code:

RS

👋 Introduction

Vehicle Segment:

Minivan

Target Audience:

Families, commercial use (taxi, shuttle services)

Key Competitors:

Dodge Grand Caravan, Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture.

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

Markets Covered:

North America, Europe (specific variants)

Estimated Pages:

1500+

Type:

Factory Service Manual (FSM)

Language:

English

Format:

PDF Download

📖 Manual Coverage

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.

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.

Depth:

Comprehensive, from basic fluid checks to complete engine and transmission overhauls.

📊 Manual Specifications

File Type:

PDF

Printability:

High-resolution, suitable for printing individual pages or the entire manual.

Binding Recommendation:

Print and spiral-bind for ease of use in a workshop environment.

Recommended Paper:

Durable, glossy paper for workshop conditions.

⚙️ Engine Specifications

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

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

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 Delivery:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline

Recommended Octane:

87 (minimum)

🔧 Transmission

Transmission Type Std:

4-speed automatic (A604/A670)

Transmission Type Opt:

Not applicable (standard across powertrain options)

Transmission Features:

Driver-adaptive electronic controls, selectable gear range (AutoStick on some trims for 3.8L).

Transmission Fluid Type:

Chrysler ATF+4 (MS-9602)

Transmission Fluid Capacity:

Approx. 6.0 quarts (5.7 liters) for dry fill, 4.0 quarts (3.8 liters) for drain and refill.

📐 Dimensions

Length:

194.6 inches

Width:

77.5 inches

Height:

68.5 inches

Wheelbase:

119.2 inches

Passenger Volume:

Approx. 150.5 cubic feet

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

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

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)

ABS:

Standard

Traction Control:

Optional (TCS)

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

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.

Cruise Control:

Standard

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

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).

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.

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

Parent Company:

Chrysler Corporation (later Fiat Chrysler Automobiles, now Stellantis)

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).

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

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.

Consumer Reports Reliability:

Variable across model years and specific components. The manual is crucial for addressing potential reliability concerns.