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2004 Crossfire Chrysler ZH Service Repair Manual & Parts List

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🏷️ Basic Information Identification Make: Chrysler Model: Crossfire Year: 2004 Market Segment: Sports Car / Grand Tourer Chassis Code: ZH Codes Vin Year Indicator: 4 (for 2004 model year) 👋 Introduction Market Position Vehicle Class: Rear-wheel drive sports coupe, developed from the Mercedes-Benz R170 SLK platform. Design Origin: Designed by DaimlerChrysler, sharing significant components and design elements with the Mercedes-Benz SLK32 AMG. Competitive Analysis Key Competitors: Porsche Boxster, BMW Z4, Chevrolet Corvette (lower trims), Nissan 350Z. Key Features Unique Selling Points: Mercedes-Benz engineered chassis and powertrain components, distinctive styling, rear-wheel drive performance focus. Manual Value Proposition Reliability: Ensures correct repair procedures and parts information, critical for maintaining performance and longevity. Accuracy: Manufacturer-written content guarantees accuracy and completeness, crucial for complex modern vehicles. Parts List: Includes a parts list, facilitating identification and procurement of correct components. 📋 Manual Details Coverage Areas Primary Coverage: 2004 Chrysler Crossfire Secondary Coverage Note: Manuals are specific to model year; this covers 2004 differences. Page Count Estimated Page Count: Extensive (typical for full workshop manual, exact count not specified but implied to be comprehensive) Manual Type Type: Service Repair Manual & Parts List Language Language: English Format Format: Digital (PDF) File Structure: Single, fully bookmarked and searchable PDF 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Clutch, Driveline, Exhaust System, Fuel System, Cooling System, Emissions Control Chassis: Suspension, Brakes, Steering, Frame & Bumpers, Tires/Wheels Body: Body, Doors, Exterior Trim, Interior Trim, Heating & Air Conditioning Electrical: Audio/Video Systems, Chime/Buzzer, Electronic Control Modules (ECMs), Engine Systems (controls), Heated Systems, Horn, Ignition Control, Instrument Cluster, Lamps, Message Center, Power Systems, Restraints (Airbags), Speed Control, Vehicle Theft Security, Wipers/Washers, Wiring Diagrams Procedures Included Repair Procedures: Disassembly & Installation Procedures, Diagnostic Procedures, Component Repair Maintenance Procedures: Lubrication & Maintenance Schedules, Fluid Changes, Filter Replacements Troubleshooting: Technical Diagnostic Procedures, Symptom-based Troubleshooting Technical Depth Depth: Comprehensive Workshop Manual - Suitable for Dealership Mechanics Diagnostics: Advanced diagnostic procedures, wiring diagrams for electrical troubleshooting Illustrations: Numerous Illustrations & Diagrams 📊 Manual Specifications File Format Type: PDF Compatibility: Windows XP, Vista, 7, 8, Linux, Mac Searchability: Fully Searchable Text Print Quality Print Ability: Printable (specific pages or entire manual) Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) Manual Quality Link Integrity: All internal links functional ⚙️ Engine Specifications Primary Engine Configuration: 3.2L V6 SOHC 18 Valve Engine Code: M112 E32 (Mercedes-Benz origin) Performance Horsepower: 215 hp @ 6000 rpm (Naturally Aspirated) Torque: 229 lb-ft @ 3000-4800 rpm (Naturally Aspirated) Fuel System Injection: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Premium Unleaded Gasoline (91 Octane or higher recommended) Cooling System Coolant Type: Chrysler HOAT (Hybrid Organic Acid Technology) antifreeze or equivalent (e.g., Pentofrost G12/G12+) Lubrication Oil Type: SAE 0W-40 or 5W-40 Synthetic (per service manual) Oil Capacity: Approximately 7.2 US quarts (6.8 Liters) with filter change 🔧 Transmission Standard Transmission Type: 5-speed Automatic Transmission Transmission Code Automatic: NAG1 (W5A580) - Mercedes-Benz 5G-TRONIC Optional Transmission Type: 6-speed Manual Transmission Transmission Code Manual: DGU Features Automatic Features: Selectable shift modes (e.g., Comfort/Sport), electronic control. Manual Features: Performance-oriented gearing, hydraulic clutch actuation. Fluid Specifications Automatic Fluid Type: Genuine Mercedes-Benz MB 236.10 (or equivalent approved ATF) Fluid Specifications Manual Fluid Type: SAE 75W-85 GL-4 or GL-5 Synthetic Gear Oil (Verify specific requirement in manual) 📐 Dimensions Exterior Length: 166.7 inches (4234 mm) Width: 70.0 inches (1778 mm) Height: 51.6 inches (1311 mm) Wheelbase: 97.2 inches (2469 mm) Weights Curb Weight Automatic: Approx. 3,310 lbs (1501 kg) Curb Weight Manual: Approx. 3,252 lbs (1475 kg) Gross Vehicle Weight Rating: Typically around 4,012 lbs (1819 kg) Cargo Trunk Volume: Approximately 8.0 cubic feet (0.226 m³) 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: Not rated for this specific year/model, but the platform generally performed well. NHTSA Frontal Impact Passenger: Not rated for this specific year/model, but the platform generally performed well. Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Standard Traction Control System (TCS) Electronic Stability: Standard Electronic Stability Program (ESP) - Mercedes-Benz ADAPTIVE ESP Passive Features Airbags Front: Driver and Passenger Frontal Airbags Airbags Side: Standard Side-impact Airbags Seatbelts: Three-point seatbelts with pretensioners 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with CD player and optional Boston Acoustics premium sound system. Navigation: Optional factory navigation system available on some trims. Driver Assistance Cruise Control: Standard Speed Control (Cruise Control) Connectivity Auxiliary Input: No standard auxiliary audio input or USB ports; aftermarket solutions may exist. 🔧 Maintenance Service Intervals Oil And Filter Change: Every 7,500 - 10,000 miles or 12 months, whichever comes first (synthetic oil recommended). Air Filter Replacement: Inspect every 15,000 miles, replace as needed (typically every 30,000 miles). Cabin Air Filter Replacement: Inspect every 15,000 miles, replace as needed (typically every 15,000-30,000 miles). Coolant Flush: Every 30,000 - 50,000 miles or 2-3 years. Transmission Fluid Change Automatic: Recommended around 60,000 miles...
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Sku: 321957
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2004 Crossfire Chrysler ZH Service Repair Manual & Parts List
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Crossfire
Year:
2004
Market Segment:
Sports Car / Grand Tourer
Chassis Code:
ZH
Codes
Vin Year Indicator:
4 (for 2004 model year)
👋 Introduction
Market Position
Vehicle Class:
Rear-wheel drive sports coupe, developed from the Mercedes-Benz R170 SLK platform.
Design Origin:
Designed by DaimlerChrysler, sharing significant components and design elements with the Mercedes-Benz SLK32 AMG.
Competitive Analysis
Key Competitors:
Porsche Boxster, BMW Z4, Chevrolet Corvette (lower trims), Nissan 350Z.
Key Features
Unique Selling Points:
Mercedes-Benz engineered chassis and powertrain components, distinctive styling, rear-wheel drive performance focus.
Manual Value Proposition
Reliability:
Ensures correct repair procedures and parts information, critical for maintaining performance and longevity.
Accuracy:
Manufacturer-written content guarantees accuracy and completeness, crucial for complex modern vehicles.
Parts List:
Includes a parts list, facilitating identification and procurement of correct components.
📋 Manual Details
Coverage Areas
Primary Coverage:
2004 Chrysler Crossfire
Secondary Coverage Note:
Manuals are specific to model year; this covers 2004 differences.
Page Count
Estimated Page Count:
Extensive (typical for full workshop manual, exact count not specified but implied to be comprehensive)
Manual Type
Type:
Service Repair Manual & Parts List
Language
Language:
English
Format
Format:
Digital (PDF)
File Structure:
Single, fully bookmarked and searchable PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Transmission, Clutch, Driveline, Exhaust System, Fuel System, Cooling System, Emissions Control
Chassis:
Suspension, Brakes, Steering, Frame & Bumpers, Tires/Wheels
Body:
Body, Doors, Exterior Trim, Interior Trim, Heating & Air Conditioning
Electrical:
Audio/Video Systems, Chime/Buzzer, Electronic Control Modules (ECMs), Engine Systems (controls), Heated Systems, Horn, Ignition Control, Instrument Cluster, Lamps, Message Center, Power Systems, Restraints (Airbags), Speed Control, Vehicle Theft Security, Wipers/Washers, Wiring Diagrams
Procedures Included
Repair Procedures:
Disassembly & Installation Procedures, Diagnostic Procedures, Component Repair
Maintenance Procedures:
Lubrication & Maintenance Schedules, Fluid Changes, Filter Replacements
Troubleshooting:
Technical Diagnostic Procedures, Symptom-based Troubleshooting
Technical Depth
Depth:
Comprehensive Workshop Manual - Suitable for Dealership Mechanics
Diagnostics:
Advanced diagnostic procedures, wiring diagrams for electrical troubleshooting
Illustrations:
Numerous Illustrations & Diagrams
📊 Manual Specifications
File Format
Type:
PDF
Compatibility:
Windows XP, Vista, 7, 8, Linux, Mac
Searchability:
Fully Searchable Text
Print Quality
Print Ability:
Printable (specific pages or entire manual)
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
Manual Quality
Link Integrity:
All internal links functional
⚙️ Engine Specifications
Primary Engine
Configuration:
3.2L V6 SOHC 18 Valve
Engine Code:
M112 E32 (Mercedes-Benz origin)
Performance
Horsepower:
215 hp @ 6000 rpm (Naturally Aspirated)
Torque:
229 lb-ft @ 3000-4800 rpm (Naturally Aspirated)
Fuel System
Injection:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91 Octane or higher recommended)
Cooling System
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) antifreeze or equivalent (e.g., Pentofrost G12/G12+)
Lubrication
Oil Type:
SAE 0W-40 or 5W-40 Synthetic (per service manual)
Oil Capacity:
Approximately 7.2 US quarts (6.8 Liters) with filter change
🔧 Transmission
Standard
Transmission Type:
5-speed Automatic Transmission
Transmission Code Automatic:
NAG1 (W5A580) - Mercedes-Benz 5G-TRONIC
Optional
Transmission Type:
6-speed Manual Transmission
Transmission Code Manual:
DGU
Features
Automatic Features:
Selectable shift modes (e.g., Comfort/Sport), electronic control.
Manual Features:
Performance-oriented gearing, hydraulic clutch actuation.
Fluid Specifications Automatic
Fluid Type:
Genuine Mercedes-Benz MB 236.10 (or equivalent approved ATF)
Fluid Specifications Manual
Fluid Type:
SAE 75W-85 GL-4 or GL-5 Synthetic Gear Oil (Verify specific requirement in manual)
📐 Dimensions
Exterior
Length:
166.7 inches (4234 mm)
Width:
70.0 inches (1778 mm)
Height:
51.6 inches (1311 mm)
Wheelbase:
97.2 inches (2469 mm)
Weights
Curb Weight Automatic:
Approx. 3,310 lbs (1501 kg)
Curb Weight Manual:
Approx. 3,252 lbs (1475 kg)
Gross Vehicle Weight Rating:
Typically around 4,012 lbs (1819 kg)
Cargo
Trunk Volume:
Approximately 8.0 cubic feet (0.226 m³)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
Not rated for this specific year/model, but the platform generally performed well.
NHTSA Frontal Impact Passenger:
Not rated for this specific year/model, but the platform generally performed well.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Standard Traction Control System (TCS)
Electronic Stability:
Standard Electronic Stability Program (ESP) - Mercedes-Benz ADAPTIVE ESP
Passive Features
Airbags Front:
Driver and Passenger Frontal Airbags
Airbags Side:
Standard Side-impact Airbags
Seatbelts:
Three-point seatbelts with pretensioners
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with CD player and optional Boston Acoustics premium sound system.
Navigation:
Optional factory navigation system available on some trims.
Driver Assistance
Cruise Control:
Standard Speed Control (Cruise Control)
Connectivity
Auxiliary Input:
No standard auxiliary audio input or USB ports; aftermarket solutions may exist.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 7,500 - 10,000 miles or 12 months, whichever comes first (synthetic oil recommended).
Air Filter Replacement:
Inspect every 15,000 miles, replace as needed (typically every 30,000 miles).
Cabin Air Filter Replacement:
Inspect every 15,000 miles, replace as needed (typically every 15,000-30,000 miles).
Coolant Flush:
Every 30,000 - 50,000 miles or 2-3 years.
Transmission Fluid Change Automatic:
Recommended around 60,000 miles or based on driving conditions (refer to manual for specific guidance on NAG1).
Transmission Fluid Change Manual:
Recommended around 60,000 miles or every 4 years.
Fluid Specifications
Power Steering Fluid:
Chrysler Power Steering Fluid or equivalent specified type.
Brake Fluid:
DOT 4
Known Issues
Common Wear Items:
Suspension bushings, ball joints, wheel bearings, and exhaust system components due to vehicle's sporty nature.
Electrical Concerns:
Occasional issues with window regulators, heated seat elements, and sometimes control module glitches.
Transmission Nags:
The NAG1 transmission can be sensitive to fluid level and type; proper maintenance is crucial.
Parts List Benefit
Parts Identification:
Crucial for ordering correct replacement parts, especially for shared Mercedes-Benz components, preventing costly mistakes.
📚 Vehicle History
Brand Heritage
Parent Company At Time:
DaimlerChrysler AG (formed from merger of Daimler-Benz and Chrysler Corporation)
Model Evolution
Development Basis:
Based on the second-generation Mercedes-Benz SLK platform (R170), specifically the SLK32 AMG components were heavily utilized.
Production
Production Period:
2003-2008
Manufacturing Location:
Karmann factory in Osnabrück, Germany
2004 Model Year Distinction:
Initial year of production for the Crossfire, establishing its market presence.
🏆 Awards & Recognition
Recognitions
Design Awards:
Recognized for its distinctive styling, often praised for its unique blend of American and European design cues.
Ratings
Consumer Reports Reliability:
Reliability ratings varied by year; the manual is key to addressing specific maintenance needs to ensure better long-term reliability.
Certifications
Manufacturing Standards:
Built to DaimlerChrysler and German automotive manufacturing standards.
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