Chrysler 300M Concorde Intrepid 2004 Repair Service Manual

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🏷️ Basic Information Identification Make: Chrysler Models Covered: • 300M • Concorde • Intrepid Model Years Covered: • 2004 Generation Chrysler 300M Generation: Second Generation (1999-2004) Chrysler Concorde Generation: Second Generation (1998-2004) Chrysler Intrepid Generation: Second Generation (1998-2004) Codes Platform Shared: Chrysler LH Platform 👋 Introduction Market Position Vehicle Segment: Full-size Sedan, Luxury-leaning Target Demographic: Families and individuals seeking comfortable, spacious, and stylish American sedans. Competitive Analysis Key Competitors: Ford Crown Victoria, Mercury Grand Marquis, Chevrolet Impala, Buick LeSabre, Toyota Avalon, Toyota Camry, Honda Accord. Key Features Chrysler 300M Distinction: Sportier styling, European-inspired interior, often more powerful engine options (e.g., 3.5L HO V6). Concorde And Intrepid Distinction: Emphasized comfort, spaciousness, and value, often with more accessible pricing and feature packages. Platform Synergy: Shared LH platform allowed for economies of scale and commonality in engineering and manufacturing. 📋 Manual Details Coverage Areas Comprehensive Coverage: Yes Target Audience: Professional Technicians and Skilled DIY Enthusiasts Page Count Estimated Pages: 1500-2000 (typical for comprehensive service manuals of this era) Manual Type Type: Factory Repair Service Manual Language Primary Language: English Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul procedures, component testing, lubrication, cooling system, fuel system, exhaust system. Engine Performance: Ignition system, fuel injection (MPI), emission controls, engine diagnostics, power output. Transmission Automatic: 42LE (and potentially others depending on specific engine) - diagnostics, overhaul, fluid service, torque converter. Drivetrain: Front-wheel drive axle shafts, differential, wheel bearings. Brakes: Hydraulic system, ABS, rotor and pad replacement, caliper service, bleeding procedures, parking brake. Suspension: Front and rear suspension components, alignment specifications, shock absorbers, struts, bushings. Steering: Power steering system, steering column, tie rod ends, rack and pinion. Electrical System: Battery, charging system, starting system, lighting, wipers, horn, power accessories. Body And Frame: Body panel removal and installation, glass replacement, interior trim, structural repair basics. Climate Control: HVAC system operation, refrigerant service, blower motor, climate control module. Diagnostics Troubleshooting: Extensive diagnostic charts, symptom-based troubleshooting, OBD-II codes and procedures. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement. Component Replacement: Alternator, starter, water pump, fuel pump, pulleys, belts, sensors, ignition coils. Engine Rebuilding: Cylinder head removal and installation, piston and connecting rod service, crankshaft service, timing chain/belt replacement. Transmission Repair: Internal transmission component replacement, valve body service, seal replacement. Brake System Service: Brake line replacement, master cylinder overhaul, power booster testing. Suspension Component Replacement: Ball joints, control arm bushings, tie rod ends, sway bar links. Electrical Component Testing: Voltage, resistance, and continuity testing of wiring harnesses and components. Body Repair Minor: Door panel removal, bumper cover replacement, headlight/taillight assembly replacement. Technical Depth Depth: Factory-level detail, including torque specifications, clearances, diagnostic flowcharts, and wiring diagrams. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems. Diagnostic Codes: Detailed explanations of OBD-II trouble codes (DTCs) and their diagnostic procedures. 📊 Manual Specifications File Format Quality: High-resolution, searchable PDF Searchability: Full text search capabilities Print Quality Printer Friendliness: Optimized for printing specific sections or the entire manual. Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine 3 5L V6 Sohc: Displacement: 3.5 Liters (3518cc). Configuration: V6. Valve Train: SOHC (Single Overhead Cam). Power: Approx. 214-225 hp @ 5800-6000 rpm. Torque: Approx. 231-240 lb-ft @ 3500-4000 rpm. Engine 3 5L V6 Sohc Ho: Displacement: 3.5 Liters (3518cc). Configuration: V6. Valve Train: SOHC (Single Overhead Cam). Power: Approx. 250-255 hp @ 6400 rpm. Torque: Approx. 250-255 lb-ft @ 3900 rpm (High Output variant, often in 300M). Engine 2 7L V6 DOHc: Displacement: 2.7 Liters (2736cc). Configuration: V6. Valve Train: DOHC (Dual Overhead Cam). Power: Approx. 200 hp @ 6400 rpm. Torque: Approx. 190 lb-ft @ 4000 rpm (often found in base Concorde/Intrepid). Performance Bore X Stroke 3 5L: 96.0 mm x 81.0 mm Compression Ratio 3 5L: 9.6:1 (standard), 10.0:1 (HO) Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: 87 Octane (Minimum) Ignition System: Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or coil packs. 🔧 Transmission Standard Transmission Type: 4-Speed Automatic Transaxle Common Transmission Model: 42LE (for 3.5L V6) / 41TE (for 2.7L V6) Optional Optional Transmission: Manual transmission was not offered on these models for the 2004 model year. Features Transmission Control: Electronic control with adaptive shift logic. Torque Converter Lock-Up: Variable lock-up clutch for improved fuel economy. 📐 Dimensions Exterior Length 300M: Approx. 201.0 inches Length Concorde Intrepid: Approx. 203.7 inches Width: Approx. 74.4 inches Height: Approx. 56.7 inches Wheelbase: Approx. 113.0 inches Interior Passenger Volume: Approx. 100-105 cubic feet (depending on model) Cargo Volume: Approx. 16-18 cubic feet (depending on model) Weights Curb Weight: Approx. 3600 - 3900 lbs (depending on engine and trim) Gross Vehicle Weight Rating Gvwr: Approx. 4700 - 4900 lbs 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 Stars...

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Description

🏷️ Basic Information

Identification

Make:

Chrysler

Models Covered:

• 300M

• Concorde

• Intrepid

Model Years Covered:

• 2004

Generation

Chrysler 300M Generation:

Second Generation (1999-2004)

Chrysler Concorde Generation:

Second Generation (1998-2004)

Chrysler Intrepid Generation:

Second Generation (1998-2004)

Codes

Platform Shared:

Chrysler LH Platform

👋 Introduction

Market Position

Vehicle Segment:

Full-size Sedan, Luxury-leaning

Target Demographic:

Families and individuals seeking comfortable, spacious, and stylish American sedans.

Competitive Analysis

Key Competitors:

Ford Crown Victoria, Mercury Grand Marquis, Chevrolet Impala, Buick LeSabre, Toyota Avalon, Toyota Camry, Honda Accord.

Key Features

Chrysler 300M Distinction:

Sportier styling, European-inspired interior, often more powerful engine options (e.g., 3.5L HO V6).

Concorde And Intrepid Distinction:

Emphasized comfort, spaciousness, and value, often with more accessible pricing and feature packages.

Platform Synergy:

Shared LH platform allowed for economies of scale and commonality in engineering and manufacturing.

📋 Manual Details

Coverage Areas

Comprehensive Coverage:

Target Audience:

Professional Technicians and Skilled DIY Enthusiasts

Page Count

Estimated Pages:

1500-2000 (typical for comprehensive service manuals of this era)

Manual Type

Type:

Factory Repair Service Manual

Language

Primary Language:

English

Format

Digital Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed overhaul procedures, component testing, lubrication, cooling system, fuel system, exhaust system.

Engine Performance:

Ignition system, fuel injection (MPI), emission controls, engine diagnostics, power output.

Transmission Automatic:

42LE (and potentially others depending on specific engine) - diagnostics, overhaul, fluid service, torque converter.

Drivetrain:

Front-wheel drive axle shafts, differential, wheel bearings.

Brakes:

Hydraulic system, ABS, rotor and pad replacement, caliper service, bleeding procedures, parking brake.

Suspension:

Front and rear suspension components, alignment specifications, shock absorbers, struts, bushings.

Steering:

Power steering system, steering column, tie rod ends, rack and pinion.

Electrical System:

Battery, charging system, starting system, lighting, wipers, horn, power accessories.

Body And Frame:

Body panel removal and installation, glass replacement, interior trim, structural repair basics.

Climate Control:

HVAC system operation, refrigerant service, blower motor, climate control module.

Diagnostics Troubleshooting:

Extensive diagnostic charts, symptom-based troubleshooting, OBD-II codes and procedures.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement.

Component Replacement:

Alternator, starter, water pump, fuel pump, pulleys, belts, sensors, ignition coils.

Engine Rebuilding:

Cylinder head removal and installation, piston and connecting rod service, crankshaft service, timing chain/belt replacement.

Transmission Repair:

Internal transmission component replacement, valve body service, seal replacement.

Brake System Service:

Brake line replacement, master cylinder overhaul, power booster testing.

Suspension Component Replacement:

Ball joints, control arm bushings, tie rod ends, sway bar links.

Electrical Component Testing:

Voltage, resistance, and continuity testing of wiring harnesses and components.

Body Repair Minor:

Door panel removal, bumper cover replacement, headlight/taillight assembly replacement.

Technical Depth

Depth:

Factory-level detail, including torque specifications, clearances, diagnostic flowcharts, and wiring diagrams.

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems.

Diagnostic Codes:

Detailed explanations of OBD-II trouble codes (DTCs) and their diagnostic procedures.

📊 Manual Specifications

File Format

Quality:

High-resolution, searchable PDF

Searchability:

Full text search capabilities

Print Quality

Printer Friendliness:

Optimized for printing specific sections or the entire manual.

Binding Type

Digital Binding:

N/A (Digital Download)

Paper Type

Digital Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine 3 5L V6 Sohc:

Displacement: 3.5 Liters (3518cc). Configuration: V6. Valve Train: SOHC (Single Overhead Cam). Power: Approx. 214-225 hp @ 5800-6000 rpm. Torque: Approx. 231-240 lb-ft @ 3500-4000 rpm.

Engine 3 5L V6 Sohc Ho:

Displacement: 3.5 Liters (3518cc). Configuration: V6. Valve Train: SOHC (Single Overhead Cam). Power: Approx. 250-255 hp @ 6400 rpm. Torque: Approx. 250-255 lb-ft @ 3900 rpm (High Output variant, often in 300M).

Engine 2 7L V6 DOHc:

Displacement: 2.7 Liters (2736cc). Configuration: V6. Valve Train: DOHC (Dual Overhead Cam). Power: Approx. 200 hp @ 6400 rpm. Torque: Approx. 190 lb-ft @ 4000 rpm (often found in base Concorde/Intrepid).

Performance

Bore X Stroke 3 5L:

96.0 mm x 81.0 mm

Compression Ratio 3 5L:

9.6:1 (standard), 10.0:1 (HO)

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

87 Octane (Minimum)

Ignition System:

Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or coil packs.

🔧 Transmission

Standard

Transmission Type:

4-Speed Automatic Transaxle

Common Transmission Model:

42LE (for 3.5L V6) / 41TE (for 2.7L V6)

Optional

Optional Transmission:

Manual transmission was not offered on these models for the 2004 model year.

Features

Transmission Control:

Electronic control with adaptive shift logic.

Torque Converter Lock-Up:

Variable lock-up clutch for improved fuel economy.

📐 Dimensions

Exterior

Length 300M:

Approx. 201.0 inches

Length Concorde Intrepid:

Approx. 203.7 inches

Width:

Approx. 74.4 inches

Height:

Approx. 56.7 inches

Wheelbase:

Approx. 113.0 inches

Interior

Passenger Volume:

Approx. 100-105 cubic feet (depending on model)

Cargo Volume:

Approx. 16-18 cubic feet (depending on model)

Weights

Curb Weight:

Approx. 3600 - 3900 lbs (depending on engine and trim)

Gross Vehicle Weight Rating Gvwr:

Approx. 4700 - 4900 lbs

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

4 Stars (2004 models)

NHTSA Front Impact Passenger:

4 Stars (2004 models)

NHTSA Side Impact Front Driver:

5 Stars (2004 models)

NHTSA Side Impact Front Passenger:

5 Stars (2004 models)

NHTSA Side Impact Rear Driver:

4 Stars (2004 models)

NHTSA Side Impact Rear Passenger:

4 Stars (2004 models)

IIHS Frontal Offset:

Good (for 300M, Concorde, Intrepid)

Active Features

Standard on all models

Traction Control:

Optional on some trims, standard on higher trims (e.g., 300M)

Passive Features

Airbags Front:

Driver and front passenger airbags

Airbags Side:

Optional front side-impact airbags

Seatbelts:

Three-point seatbelts with pretensioners in front.

💡 Technology Features

Infotainment

Audio System:

Premium Infinity stereo systems were often available, featuring multiple speakers and subwoofer options.

Navigation:

Optional factory navigation systems were available on higher trims.

Climate Control Interface:

Automatic climate control with digital displays was common.

Driver Assistance

Cruise Control:

Standard cruise control.

Rear Obstacle Detection:

Optional ParkSense rear parking assist system.

Connectivity

Keyless Entry:

Standard keyless entry and remote start (on some trims).

Telematics:

Early Uconnect or similar telematics systems may have been available as an option, though less sophisticated than modern systems.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles or 3-6 months (recommended, refer to owner's manual for specific synthetic oil intervals).

Air Filter Replacement:

Every 15,000-30,000 miles or as needed based on driving conditions.

Spark Plug Replacement:

3.5L HO V6: Approx. 100,000 miles (platinum/iridium). 2.7L/3.5L V6: Approx. 30,000-60,000 miles (copper/platinum, depending on specific plug type).

Transmission Fluid Change:

Every 30,000-60,000 miles (recommended, depending on driving conditions and fluid type).

Coolant Flush:

Every 30,000-50,000 miles or 2-3 years.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (API Certified, meets Chrysler MS-6395T)

Engine Oil Capacity 3 5L:

Approx. 4.5 US quarts (with filter)

Engine Oil Capacity 2 7L:

Approx. 3.5 US quarts (with filter)

Transmission Fluid Type:

ATF+4 (Chrysler MS-9602)

Transmission Fluid Capacity 42Le:

Approx. 4.0 US quarts (dry fill)

Coolant Type:

Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, Blue (meets Chrysler MS-9769).

Power Steering Fluid:

ATF+4 (Chrysler MS-9602) or a compatible power steering fluid.

Brake Fluid Type:

DOT 3 (or DOT 4, if specified for ABS)

Known Issues

Engine Mounts:

Premature failure of engine mounts, especially on the 3.5L engines, leading to vibrations.

Transmission Shifting Issues:

Occasional harsh shifting or transmission slipping in the 42LE and 41TE automatics, often related to solenoids or valve body issues.

Heater Core Leaks:

Leaking heater cores, a common issue in many vehicles of this era, causing coolant loss and fogging of the windshield.

Power Window Motors:

Failure of power window regulators and motors.

Cv Axle Boots:

Tearing of CV axle boots, leading to loss of grease and potential axle failure.

📚 Vehicle History

Brand Heritage

Chrysler Legacy:

Chrysler has a long history of producing comfortable, spacious, and often technologically advanced sedans.

Model Evolution

Lh Platform Debut:

The LH platform debuted in 1993 and underwent significant updates for the second generation in 1998, which included the 300M, Concorde, and Intrepid.

300M Positioning:

The 300M was positioned as the sportiest and most luxurious variant, offering a more upscale experience.

Concorde And Intrepid Positioning:

The Concorde and Intrepid shared a platform and offered varying levels of luxury and performance, with the Concorde generally being the more premium offering.

Production

Manufacturing Location:

Brampton Assembly Plant, Ontario, Canada

Production Years For Models:

300M: 1999-2004. Concorde: 1998-2004. Intrepid: 1998-2004.

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

The Chrysler LH platform models, including the 300M and Concorde, were often recognized for their value and comfortable ride, though not consistently on '10 Best' lists for this specific year.

Jd Power Ratings:

Ratings varied by model and year, with some models performing better in initial quality and dependability surveys than others. The 300M often received higher marks for performance and styling.

Certifications

Emissions Certification:

All models met EPA and California emissions standards for the 2004 model year.