Chrysler Crossfire 2003-2007 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Crossfire Model Years Covered: 2003, 2004, 2005, 2006, 2007 Body Styles Covered: Coupe, Roadster (Convertible) Codes Chassis Code: ZH 👋 Introduction Market Position Segment: Rear-wheel drive, sports coupe/roadster. Development Origin: Based on the Mercedes-Benz R170 SLK platform. Competitive Analysis Competitors: Chevrolet Corvette (C5/C6), Ford Mustang, Porsche Boxster, BMW Z4. Key Features Design Philosophy: Performance-oriented, European styling cues, driver-focused cockpit. Platform Sharing: Leveraged DaimlerChrysler partnership for platform and some component sharing with Mercedes-Benz. 📋 Manual Details Coverage Areas Language: English Geographic Market: North America (primarily, based on Chrysler branding) Page Count Estimated Pages: Over 2000 (typical for a comprehensive factory service manual) Manual Type Manual Type: Factory Service Manual / Workshop Manual Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, inspection, repair procedures for all engine variants. Engine Management: Fuel injection, ignition system, emissions control, diagnosis of engine control module (ECM) codes and operation. Transmission Manual: Service and repair for manual transmissions, clutch system, linkage. Transmission Automatic: Service and repair for automatic transmissions, torque converter, shift controls, fluid cooling. Drivetrain: Rear-wheel drive system, driveshaft, differential, axles, bearings. Suspension: Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment specifications. Steering: Power steering system, steering column, rack and pinion, tie rods, hydraulic components. Brakes: Hydraulic system, ABS, EBD, brake pads, rotors, calipers, lines, parking brake, bleeding procedures. Electrical System: Battery, charging system (alternator), starting system (starter), lighting, horn, power windows, locks, mirrors. Body Electrical: Instrument cluster, body control module (BCM), HVAC controls, audio system, airbag system (SRS). HVAC: Heating, ventilation, and air conditioning system diagnosis and repair, refrigerant handling, components. Body And Frame: Body panel removal/installation, doors, hood, trunk lid, glass, interior trim, structural components. Restraint Systems: Airbag system (SRS) components, diagnosis, replacement procedures, seat belts. Diagnostics: Troubleshooting charts, diagnostic trouble codes (DTCs), scan tool usage, wiring diagrams. Procedures Included Scheduled Maintenance: Detailed schedules for oil changes, filter replacements, fluid checks, spark plugs, belts, etc. Routine Inspections: Visual checks and functional tests for various vehicle systems. Component Removal Installation: Step-by-step guides for replacing major and minor components. Engine Rebuilding: Overhaul procedures, torque specifications, clearance measurements, piston ring installation, bearing replacement. Transmission Overhaul: Disassembly, inspection, and reassembly of automatic and manual transmissions. Brake System Repair: Pad/rotor replacement, caliper service, bleeding, ABS component replacement. Electrical Troubleshooting: Using wiring diagrams to diagnose electrical faults, component testing. Air Conditioning Service: Refrigerant recovery, charging, leak detection, component replacement. Bodywork Repair: Panel alignment, dent repair guidance, glass replacement. Diagnostic Troubleshooting Charts: Flowcharts for identifying and resolving common issues. Technical Depth Depth Of Information: Comprehensive, covering all aspects from basic maintenance to complete engine and transmission overhauls. Diagnostic Capabilities: Detailed diagnostic procedures, DTC interpretations, sensor data analysis where applicable. Specifications Accuracy: Factory-level precision in torque values, clearances, fluid capacities, and diagnostic parameters. Wiring Diagrams: Detailed and often color-coded wiring schematics for all major systems. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval. Print Quality Image Resolution: High-resolution for clear diagrams, illustrations, and photos. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: M112 E32 Engine Type: 3.2L V6 SOHC (18 valve) Engine Aspirated: Naturally Aspirated Performance Horsepower Std Engine: 215 hp @ 6000 rpm Torque Std Engine: 229 lb-ft @ 3000 rpm Horsepower Srt6: 350 hp @ 6100 rpm Torque Srt6: 350 lb-ft @ 3500 rpm Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded gasoline, 89 octane minimum recommended Engine Codes Additional Supercharged Engine Code: M112 ML55 (modified for SRT6) Supercharged Engine Type: 3.2L V6 Supercharged SOHC (18 valve) 🔧 Transmission Standard Transmission Std Engine: 6-speed Manual Optional Transmission Opt Engine: 5-speed Automatic (Mercedes-Benz 5G-Tronic) Transmission Srt6: 5-speed Automatic (Mercedes-Benz 5G-Tronic, performance tuned) Features Drivetrain: Rear-Wheel Drive (RWD) Transmission Fluid Spec Auto: MB Spec 236.10 / 236.12 (e.g., Pentosin ATF1, Mobil 1 ATF) Transmission Fluid Capacity Auto: Approx. 8.5 liters (17.9 US pints) for total fill Transmission Fluid Spec Manual: MB Spec 235.10 (GL-4 SAE 75W-85) or equivalent 📐 Dimensions Exterior Length: 169.1 inches (430 cm) Width: 70.4 inches (178.8 cm) Height Coupe: 53.7 inches (136.4 cm) Height Roadster: 53.2 inches (135.1 cm) Wheelbase: 99.1 inches (251.7 cm) Front Track: 59.3 inches (150.6 cm) Rear Track: 58.3 inches (148.1 cm) Cargo Cargo Volume Coupe: 10.6 cu ft (300 liters) Cargo Volume Roadster: 7.7 cu ft (218 liters) Weights Curb Weight Std Coupe: 3,197 lbs (1,450 kg) Curb Weight Std Roadster: 3,329 lbs (1,510 kg) Curb Weight Srt6 Coupe: 3,351 lbs (1,520 kg) Curb Weight Srt6 Roadster: 3,472 lbs (1,575 kg) Towing Capacity: Not Recommended 🛡️ Safety Features Ratings NHTSA Rollover Rating Coupe: 4/5 stars NHTSA Rollover Rating Roadster: 5/5 stars Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Standard Traction...

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Tags: 2003 2004 2005 2006 2007 Car Chrysler Crossfire Marine Misc Outboard Engines

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Description

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Crossfire

Model Years Covered:

2003, 2004, 2005, 2006, 2007

Body Styles Covered:

Coupe, Roadster (Convertible)

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Rear-wheel drive, sports coupe/roadster.

Development Origin:

Based on the Mercedes-Benz R170 SLK platform.

Competitive Analysis

Competitors:

Chevrolet Corvette (C5/C6), Ford Mustang, Porsche Boxster, BMW Z4.

Key Features

Design Philosophy:

Performance-oriented, European styling cues, driver-focused cockpit.

Platform Sharing:

Leveraged DaimlerChrysler partnership for platform and some component sharing with Mercedes-Benz.

📋 Manual Details

Coverage Areas

Language:

English

Geographic Market:

North America (primarily, based on Chrysler branding)

Page Count

Estimated Pages:

Over 2000 (typical for a comprehensive factory service manual)

Manual Type

Manual Type:

Factory Service Manual / Workshop Manual

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, inspection, repair procedures for all engine variants.

Engine Management:

Fuel injection, ignition system, emissions control, diagnosis of engine control module (ECM) codes and operation.

Transmission Manual:

Service and repair for manual transmissions, clutch system, linkage.

Transmission Automatic:

Service and repair for automatic transmissions, torque converter, shift controls, fluid cooling.

Drivetrain:

Rear-wheel drive system, driveshaft, differential, axles, bearings.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment specifications.

Steering:

Power steering system, steering column, rack and pinion, tie rods, hydraulic components.

Brakes:

Hydraulic system, ABS, EBD, brake pads, rotors, calipers, lines, parking brake, bleeding procedures.

Electrical System:

Battery, charging system (alternator), starting system (starter), lighting, horn, power windows, locks, mirrors.

Body Electrical:

Instrument cluster, body control module (BCM), HVAC controls, audio system, airbag system (SRS).

HVAC:

Heating, ventilation, and air conditioning system diagnosis and repair, refrigerant handling, components.

Body And Frame:

Body panel removal/installation, doors, hood, trunk lid, glass, interior trim, structural components.

Restraint Systems:

Airbag system (SRS) components, diagnosis, replacement procedures, seat belts.

Diagnostics:

Troubleshooting charts, diagnostic trouble codes (DTCs), scan tool usage, wiring diagrams.

Procedures Included

Scheduled Maintenance:

Detailed schedules for oil changes, filter replacements, fluid checks, spark plugs, belts, etc.

Routine Inspections:

Visual checks and functional tests for various vehicle systems.

Component Removal Installation:

Step-by-step guides for replacing major and minor components.

Engine Rebuilding:

Overhaul procedures, torque specifications, clearance measurements, piston ring installation, bearing replacement.

Transmission Overhaul:

Disassembly, inspection, and reassembly of automatic and manual transmissions.

Brake System Repair:

Pad/rotor replacement, caliper service, bleeding, ABS component replacement.

Electrical Troubleshooting:

Using wiring diagrams to diagnose electrical faults, component testing.

Air Conditioning Service:

Refrigerant recovery, charging, leak detection, component replacement.

Bodywork Repair:

Panel alignment, dent repair guidance, glass replacement.

Diagnostic Troubleshooting Charts:

Flowcharts for identifying and resolving common issues.

Technical Depth

Depth Of Information:

Comprehensive, covering all aspects from basic maintenance to complete engine and transmission overhauls.

Diagnostic Capabilities:

Detailed diagnostic procedures, DTC interpretations, sensor data analysis where applicable.

Specifications Accuracy:

Factory-level precision in torque values, clearances, fluid capacities, and diagnostic parameters.

Wiring Diagrams:

Detailed and often color-coded wiring schematics for all major systems.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content for quick information retrieval.

Print Quality

Image Resolution:

High-resolution for clear diagrams, illustrations, and photos.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M112 E32

Engine Type:

3.2L V6 SOHC (18 valve)

Engine Aspirated:

Naturally Aspirated

Performance

Horsepower Std Engine:

215 hp @ 6000 rpm

Torque Std Engine:

229 lb-ft @ 3000 rpm

Horsepower Srt6:

350 hp @ 6100 rpm

Torque Srt6:

350 lb-ft @ 3500 rpm

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline, 89 octane minimum recommended

Engine Codes Additional

Supercharged Engine Code:

M112 ML55 (modified for SRT6)

Supercharged Engine Type:

3.2L V6 Supercharged SOHC (18 valve)

🔧 Transmission

Standard

Transmission Std Engine:

6-speed Manual

Optional

Transmission Opt Engine:

5-speed Automatic (Mercedes-Benz 5G-Tronic)

Transmission Srt6:

5-speed Automatic (Mercedes-Benz 5G-Tronic, performance tuned)

Features

Drivetrain:

Rear-Wheel Drive (RWD)

Transmission Fluid Spec Auto:

MB Spec 236.10 / 236.12 (e.g., Pentosin ATF1, Mobil 1 ATF)

Transmission Fluid Capacity Auto:

Approx. 8.5 liters (17.9 US pints) for total fill

Transmission Fluid Spec Manual:

MB Spec 235.10 (GL-4 SAE 75W-85) or equivalent

📐 Dimensions

Exterior

Length:

169.1 inches (430 cm)

Width:

70.4 inches (178.8 cm)

Height Coupe:

53.7 inches (136.4 cm)

Height Roadster:

53.2 inches (135.1 cm)

Wheelbase:

99.1 inches (251.7 cm)

Front Track:

59.3 inches (150.6 cm)

Rear Track:

58.3 inches (148.1 cm)

Cargo

Cargo Volume Coupe:

10.6 cu ft (300 liters)

Cargo Volume Roadster:

7.7 cu ft (218 liters)

Weights

Curb Weight Std Coupe:

3,197 lbs (1,450 kg)

Curb Weight Std Roadster:

3,329 lbs (1,510 kg)

Curb Weight Srt6 Coupe:

3,351 lbs (1,520 kg)

Curb Weight Srt6 Roadster:

3,472 lbs (1,575 kg)

Towing Capacity:

Not Recommended

🛡️ Safety Features

Ratings

NHTSA Rollover Rating Coupe:

4/5 stars

NHTSA Rollover Rating Roadster:

5/5 stars

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Standard Traction Control System (TCS)

Electronic Stability:

Standard Electronic Stability Program (ESP) - integrated with ABS and TCS.

Passive Features

Airbags:

Driver and passenger front airbags, side airbags (standard on most models).

Seat Belts:

Three-point active seat belts with pretensioners.

Roll Bars:

Integrated roll bars behind seats for Roadster models.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional premium Infinity sound system with subwoofer.

Navigation:

Optional factory navigation system (typically DVD-based).

Driver Assistance

Cruise Control:

Standard cruise control.

Tire Pressure Monitoring:

Optional Tire Pressure Monitoring System (TPMS).

Connectivity

Aux Input:

Some models may have an auxiliary input jack.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles (12,000 km) or 12 months, whichever comes first.

Engine Oil Filter Replacement:

Replace with oil change.

Air Filter Replacement:

Inspect every 7,500 miles, replace as needed or every 30,000 miles (48,000 km).

Cabin Air Filter Replacement:

Inspect every 7,500 miles, replace as needed or every 15,000 miles (24,000 km).

Spark Plug Replacement Std:

Replace at 100,000 miles (160,000 km) (long-life iridium plugs).

Coolant Replacement:

First replacement at 100,000 miles (160,000 km) or 5 years, then every 50,000 miles (80,000 km) or 2-3 years.

Fluid Specifications

Engine Oil Type:

SAE 0W-40 or 5W-40, API SN or higher, ACEA A3/B4 approved (e.g., Mobil 1 Formula M 5W-40, Valvoline SynPower MST 5W-40).

Engine Oil Capacity:

8.5 US quarts (8.0 liters) with filter change.

Coolant Type:

MB Spec 325.0 (Blue) or 326.0 (Pre-diluted Blue) - Mercedes-Benz Antifreeze/Coolant

Brake Fluid Type:

DOT 4 (or DOT 4 Plus) high-performance brake fluid.

Power Steering Fluid Type:

Pentosin CHF 11S or equivalent hydraulic fluid.

Known Issues

Common Issue Interior Rattles:

Interior trim pieces, especially around the dashboard and door panels, can develop rattles.

Common Issue Wiring Harness Issues:

Some models may experience issues with the wiring harness, particularly related to the convertible top mechanism or sensor faults.

Common Issue Convertible Top:

The hydraulic system and latches for the convertible top can require maintenance or repair.

Common Issue Accelerator Pedal Sensor:

Electronic throttle control (ETC) related issues, sometimes due to the accelerator pedal position sensor.

Common Issue Suspension Bushings:

Wear in suspension bushings can lead to noise and degraded handling over time.

Common Issue Exhaust Manifold Cracks:

Exhaust manifold cracks can occur, leading to exhaust leaks and a ticking noise.

📚 Vehicle History

Brand Heritage

Parent Company Era:

Developed during the DaimlerChrysler AG era, benefiting from shared technology.

Model Evolution

Concept To Production:

The Crossfire was a concept car first shown in 2001, entering production for the 2004 model year.

Facelift Updates:

Minor styling updates and equipment enhancements were made throughout its production run, with the SRT-6 variant introduced for 2005.

Production

Manufacturing Location:

Karmann factory in Osnabrück, Germany.

Production Years:

2003 (for 2004 MY) - 2007

Total Production Units:

Approximately 70,000 units globally.

🏆 Awards & Recognition

Recognitions

Design Awards:

The Crossfire's distinctive styling received positive mentions in automotive design circles.

Ratings

Car And Driver Comparison:

Frequently compared against established sports cars in its class during its tenure.

Certifications

Manufacturing Quality:

Built by Karmann, known for high-quality automotive manufacturing.