Chrysler Crossfire 2004-2008 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Chrysler Model: Crossfire Model Years Covered: 2004, 2005, 2006, 2007, 2008 Generation Generation Identifier: First Generation (ZH) Codes Chassis Code: ZH 👋 Introduction Market Position Positioning: A high-performance, rear-wheel-drive sports coupe/roadster with distinctive styling, positioned as a premium offering in its segment. Competitive Analysis Competitors: Competed against vehicles like the Nissan 350Z, Ford Mustang, Chevrolet Corvette (lower trims), and Mazda RX-8 during its production run. Key Features Design Origin: Based on the Mercedes-Benz R170 SLK platform, sharing significant mechanical components and development with DaimlerChrysler's previous collaboration. Performance Focus: Emphasized sporty handling, powerful engines, and a driver-centric experience. Value Proposition Diy Savings: Enables owners to perform routine maintenance and repairs, potentially saving significant costs on dealership service. Information Source Authenticity: Contains the exact same information used by authorized Chrysler technicians and dealerships. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Workshop Page Count Estimated Page Count: Extensive (Exact count not specified, but described as 'full' and covering 'all major topics') Manual Type Type: Comprehensive Service and Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed procedures for engine disassembly, assembly, diagnostics, and repair. Engine Electrical: Wiring schematics, component testing, diagnostic procedures for electrical systems. Emission Control: Information on emissions systems, diagnosis, and repair. Fuel System: Components, operation, diagnosis, and repair of the fuel delivery system. Clutch System: Clutch operation, adjustment, and replacement procedures. Manual Transaxle: Detailed repair and overhaul procedures for manual gearboxes. Automatic Transaxle: Comprehensive repair and diagnostic information for automatic transmissions. Driveshaft Axle: Service and repair of driveshafts, CV joints, and axles. Suspension System: Diagnosis, repair, and component replacement for front and rear suspension. Steering System: Repair and service for the steering rack, power steering system, and components. Restraint System: Information on airbags, seatbelts, and associated safety systems. Brake System: Diagnosis, repair, and maintenance of ABS, disc/drum brakes. Body Interior Exterior: Repair and adjustment procedures for body panels, trim, and interior components. Body Electrical: Wiring diagrams and repair for body-related electrical functions (lights, power accessories). HVAC: Service and repair of the heating, ventilation, and air conditioning systems. Procedures Included Maintenance: Routine maintenance tasks, fluid changes, filter replacements, inspections. Troubleshooting: Diagnostic flowcharts and procedures for identifying and resolving common issues. Repair: Step-by-step repair instructions for virtually all vehicle components. Diagnostics: Procedures for diagnosing electrical and mechanical faults using specialized tools and techniques. Installation: Instructions for installing replacement parts and accessories. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete overhauls and advanced diagnostics. Target Audience: Professional mechanics, independent repair shops, and experienced DIY enthusiasts. 📊 Manual Specifications File Format Format: PDF Compatibility: Windows and Mac operating systems Requirements: Adobe PDF Reader Print Quality Printability: Fully printable, allowing users to print specific pages as needed. Binding Type Binding: N/A (Digital format) Paper Type Paper Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: 3.2L V6 Supercharged (M112 E32 ML) Displacement: 3199 cc (3.2 Liters) Horsepower: 215 hp @ 5700 rpm (non-SRT6), 350 hp @ 6200 rpm (SRT6) Torque: 221 lb-ft @ 3000 rpm (non-SRT6), 339 lb-ft @ 3200 rpm (SRT6) Performance Aspiration: Supercharged (Roots-type supercharger) Cylinder Layout: V6 Bore X Stroke: 89.9 mm x 84.0 mm Fuel System Fuel Delivery: Sequential Multiport Fuel Injection (SFI) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Engine Mechanical Block Material: Aluminum alloy Cylinder Head Material: Aluminum alloy Valvetrain: Single Overhead Camshafts (SOHC) per bank, 3 valves per cylinder (2 intake, 1 exhaust) 🔧 Transmission Standard Transmission Type: 5-Speed Automatic (NAG3) Optional Transmission Type: 6-Speed Manual (sourced from Mercedes-Benz) Features Automatic Features: TouchShift manual shifting capability Fluid Specs Automatic Transmission Fluid Type: MB 236.10 (e.g., Mobil ATF 134, Shell ATF 3403) Manual Transmission Fluid Type: MB 235.10 (e.g., Pentosin MTF-LT-2 or equivalent) 📐 Dimensions Exterior Length: 4060 mm (159.8 in) Width: 1755 mm (69.1 in) Height: 1330 mm (52.4 in) Wheelbase: 2400 mm (94.5 in) Weights Curb Weight: Approximately 1475 kg (3252 lbs) for Coupe, 1500 kg (3307 lbs) for Roadster Gross Vehicle Weight Rating: Not explicitly provided, but typically around 1800-1900 kg Cargo Trunk Volume: Approx. 8.0 cu ft (Coupe), 3.5 cu ft (Roadster) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Good (for models tested) NHTSA Front Impact Passenger: Good (for models tested) IIHS Side Impact: Acceptable (for models tested) Active Features ABS: Standard Anti-lock Braking System Traction Control: Standard Traction Control System (TCS) Esp: Optional Electronic Stability Program (ESP) Passive Features Airbags Front: Dual-stage front airbags Airbags Side: Standard side-impact airbags Rollover Protection: Deployable roll bars (Roadster) 💡 Technology Features Infotainment Audio System: Optional premium audio systems (e.g., Boston Acoustics) available, featuring CD player, AM/FM radio, and sometimes navigation. Navigation: Optional factory navigation system available on some models. Driver Assistance Parking Sensors: Optional rear parking sensors available on some models. Connectivity...
Premium Unleaded Gasoline (91 octane or higher recommended)
Engine Mechanical
Block Material:
Aluminum alloy
Cylinder Head Material:
Aluminum alloy
Valvetrain:
Single Overhead Camshafts (SOHC) per bank, 3 valves per cylinder (2 intake, 1 exhaust)
🔧 Transmission
Standard
Transmission Type:
5-Speed Automatic (NAG3)
Optional
Transmission Type:
6-Speed Manual (sourced from Mercedes-Benz)
Features
Automatic Features:
TouchShift manual shifting capability
Fluid Specs
Automatic Transmission Fluid Type:
MB 236.10 (e.g., Mobil ATF 134, Shell ATF 3403)
Manual Transmission Fluid Type:
MB 235.10 (e.g., Pentosin MTF-LT-2 or equivalent)
📐 Dimensions
Exterior
Length:
4060 mm (159.8 in)
Width:
1755 mm (69.1 in)
Height:
1330 mm (52.4 in)
Wheelbase:
2400 mm (94.5 in)
Weights
Curb Weight:
Approximately 1475 kg (3252 lbs) for Coupe, 1500 kg (3307 lbs) for Roadster
Gross Vehicle Weight Rating:
Not explicitly provided, but typically around 1800-1900 kg
Cargo
Trunk Volume:
Approx. 8.0 cu ft (Coupe), 3.5 cu ft (Roadster)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Good (for models tested)
NHTSA Front Impact Passenger:
Good (for models tested)
IIHS Side Impact:
Acceptable (for models tested)
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Standard Traction Control System (TCS)
Esp:
Optional Electronic Stability Program (ESP)
Passive Features
Airbags Front:
Dual-stage front airbags
Airbags Side:
Standard side-impact airbags
Rollover Protection:
Deployable roll bars (Roadster)
💡 Technology Features
Infotainment
Audio System:
Optional premium audio systems (e.g., Boston Acoustics) available, featuring CD player, AM/FM radio, and sometimes navigation.
Navigation:
Optional factory navigation system available on some models.
Driver Assistance
Parking Sensors:
Optional rear parking sensors available on some models.
Connectivity
Bluetooth:
Not standard on most models; may have been an aftermarket or dealer-installed option.
Lighting
Headlights:
Halogen projector headlights with available Xenon HID headlights on higher trims or as an option.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 12 months (refer to manual for specific conditions)
Engine Air Filter:
Inspect every 15,000 miles, replace as needed or every 30,000 miles.
Cabin Air Filter:
Replace every 15,000 miles or 12 months.
Spark Plugs:
Replace every 100,000 miles (iridium type)
Fluid Specifications
Engine Oil Type:
SAE 0W-40 or 5W-40 Synthetic (API SN or similar)
Engine Oil Capacity:
Approximately 7.4 quarts (7.0 Liters) with filter change
Coolant Type:
Chrysler/Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, Blue (G-05 equivalent)
Brake Fluid Type:
DOT 4
Power Steering Fluid Type:
Pentosin CHF 11S or equivalent (specific to shared Mercedes-Benz system)
Known Issues
Supercharger Coupler:
Some owners report wear or failure of the supercharger decoupler, leading to reduced boost or noise. Covered in manual for diagnosis and replacement.
Interior Rattles:
As with many sports cars, interior trim pieces can develop rattles over time. Manual provides guidance on interior panel removal and reassembly.
Water Pump Leak:
Potential for water pump seal leaks, requiring replacement. Manual details the procedure.
Wiring Harness Issues:
Corrosion or damage to wiring harnesses, particularly in the engine bay or around the battery, can cause electrical gremlins. Manual's wiring diagrams are critical for troubleshooting.
📚 Vehicle History
Brand Heritage
Heritage Connection:
Chrysler's foray into a rear-wheel-drive, German-engineered sports car, leveraging the DaimlerChrysler alliance.
Model Evolution
Development Basis:
Developed in collaboration with Mercedes-Benz, utilizing the platform and many components from the SLK32 AMG.
Variants:
Available as a Coupe and a Roadster. An SRT-6 version (supercharged) was introduced in 2005.
Production
Production Period:
2003-2008
Manufacturing Location:
Graz, Austria (by Magna Steyr)
🏆 Awards & Recognition
Recognitions
Design Awards:
Praised for its distinctive styling and European-inspired design, although critical reception on overall execution was mixed.
Ratings
Consumer Reports Reliability:
Mixed reliability ratings, typical for vehicles with complex German engineering shared with a different brand. Manual is crucial for maintenance.
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