Chrysler 300 300C 300 Touring & Dodge Magnum Body Repair 2004-2011 Factory Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Chrysler, Dodge Model: Chrysler 300, Chrysler 300C, Chrysler 300 Touring, Dodge Magnum Codes Platform: LX Platform (Rear-Wheel Drive) 👋 Introduction Market Position Market Segment: Full-size luxury sedan (Chrysler 300/300C) and full-size wagon/hatchback (Dodge Magnum) Competitive Analysis Competitors: Chrysler 300: Ford Crown Victoria, Lincoln Town Car, Cadillac DTS, Buick Lucerne. Dodge Magnum: Ford Five Hundred/Taurus wagon, Subaru Outback (in its niche). Key Features Design Philosophy: Rear-wheel-drive architecture, distinctive retro-futuristic styling (Chrysler 300) and versatile wagon design (Dodge Magnum) Target Audience: Buyers seeking bold styling, rear-wheel-drive performance, and spacious interiors. Manual Value Benefit For Users: Enables professional-quality body repairs, collision damage restoration, and part replacements, reducing reliance on expensive body shops. 📋 Manual Details Coverage Model Years: 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011 Coverage Areas: Body Repair Type Manual Type: Factory Service Repair Workshop Manual Format Format: Digital Download Language Language: English 📖 Manual Coverage Systems Covered Body Structure: Unibody construction, chassis, frame straightening, structural integrity Exterior Panels: Hood, fenders, doors, quarter panels, roof panel, trunk lid, bumpers Glass And Seals: Windshield, side glass, rear glass, window regulators, seals, weatherstripping Interior Trim: Dashboard, door panels, headliner, carpeting, seat upholstery repair Paint And Finishing: Surface preparation, priming, painting techniques, clear coat application, rust prevention Restoration: Repair of collision damage, rust repair, part replacement procedures Procedures Included Disassembly Assembly: Detailed step-by-step procedures for component removal and installation Welding And Joining: Spot welding, MIG welding, riveting, adhesive bonding techniques for body panels Panel Alignment: Gapping and alignment specifications for all exterior body panels Material Handling: Procedures for working with various body materials (steel, aluminum, plastic) Technical Depth Depth: Comprehensive, from minor dent repair to major collision structural repair Diagrams: Extensive use of exploded views, line drawings, and diagrams Wiring: Inclusion of body electrical wiring diagrams relevant to body repair and components 📊 Manual Specifications File Format File Format: PDF Searchable Text: Likely searchable (dependent on OCR quality of original document) Print Quality Print Quality: High-resolution scans suitable for printing Binding Type Binding Type: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Chrysler 300/300C (2004-2011): 2.7L V6 (2004-2007), 3.5L V6 (2004-2010), 5.7L HEMI V8 (2005-2010), 6.1L HEMI V8 (SRT8, 2005-2010) Dodge Magnum (2005-2008): 2.7L V6 (2004-2007), 3.5L V6 (2004-2008), 5.7L HEMI V8 (2005-2008), 6.1L HEMI V8 (SRT8, 2006-2008) Performance 3.5L V6: Approx. 250-255 hp, 250-250 lb-ft torque 5.7L Hemi V8: Approx. 340-360 hp, 390-395 lb-ft torque, Multi-Displacement System (MDS) 6.1L Hemi V8 (Srt8): Approx. 425 hp, 420 lb-ft torque Fuel System Type: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (Regular for 2.7L/3.5L, Premium recommended for HEMI engines) 🔧 Transmission Standard Chrysler 300/300C: 4-speed automatic (42RLE) for 2.7L V6; 5-speed automatic (W5A580) for 3.5L V6, 5.7L HEMI, 6.1L HEMI Dodge Magnum: 4-speed automatic (42RLE) for 2.7L V6; 5-speed automatic (W5A580) for 3.5L V6, 5.7L HEMI, 6.1L HEMI Optional All-Wheel-Drive: Available on some 3.5L V6 and 5.7L HEMI models (Chrysler 300/300C) Features Transmission Fluid Type: Chrysler ATF+4 (or equivalent specification for W5A580 and 42RLE) 📐 Dimensions Exterior Chrysler 300 Wheelbase: Approx. 120 inches Dodge Magnum Wheelbase: Approx. 120 inches Chrysler 300 Length: Approx. 196.8 inches Dodge Magnum Length: Approx. 199.1 inches Interior Passenger Volume: Over 100 cubic feet (class-leading for many years) Cargo Dodge Magnum Cargo Volume: Approx. 20.2 - 71.6 cubic feet (seats up/down) Weights Curb Weight Range: Approx. 3,800 - 4,300 lbs depending on engine and configuration 🛡️ Safety Features Ratings NHTSA Frontal Crash Rating: 5-Star (for driver and front passenger in most configurations) IIHS Side Impact Rating: Good (for most models) Active Features Braking: Four-wheel disc brakes with ABS standard Traction Control: Traction Control System (TCS) standard Stability Control: Electronic Stability Program (ESP/ESC) available or standard on later models Passive Features Airbags: Frontal airbags, side curtain airbags, front seat-mounted side airbags Seatbelts: Three-point seat belts with pretensioners 💡 Technology Features Infotainment Available Systems: Boston Acoustics or Infinity premium audio systems, Uconnect infotainment system with navigation (optional on later models). Driver Assistance Available Features: ParkSense parking assist, Rain-sensing wipers, HID headlamps (optional on some trims). Connectivity Available Features: Bluetooth hands-free communication via Uconnect system. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000 to 7,500 miles or 6 months, depending on driving conditions (consult owner's manual for specifics). Transmission Fluid Service: Check manual, often around 60,000-100,000 miles for replacement/flushing. Fluid Specifications Engine Oil Viscosity: 5W-20 (2.7L, 3.5L V6), 5W-20 or 5W-30 (5.7L HEMI, 6.1L HEMI - consult manual for exact specs) Coolant Type: OAT (Orange) HOAT coolant, Mopar specifications Brake Fluid Type: DOT 3 Known Issues Chrysler 300/Dodge Magnum: Early models had some reports of transmission issues (especially 42RLE), power steering pump leaks, and front suspension components. HEMI engines can be sensitive to oil viscosity. Body Specific: Rust on lower body panels and wheel arches, especially in...
Chrysler 300, Chrysler 300C, Chrysler 300 Touring, Dodge Magnum
Codes
Platform:
LX Platform (Rear-Wheel Drive)
👋 Introduction
Market Position
Market Segment:
Full-size luxury sedan (Chrysler 300/300C) and full-size wagon/hatchback (Dodge Magnum)
Competitive Analysis
Competitors:
Chrysler 300: Ford Crown Victoria, Lincoln Town Car, Cadillac DTS, Buick Lucerne. Dodge Magnum: Ford Five Hundred/Taurus wagon, Subaru Outback (in its niche).
Approx. 340-360 hp, 390-395 lb-ft torque, Multi-Displacement System (MDS)
6.1L Hemi V8 (Srt8):
Approx. 425 hp, 420 lb-ft torque
Fuel System
Type:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (Regular for 2.7L/3.5L, Premium recommended for HEMI engines)
🔧 Transmission
Standard
Chrysler 300/300C:
4-speed automatic (42RLE) for 2.7L V6; 5-speed automatic (W5A580) for 3.5L V6, 5.7L HEMI, 6.1L HEMI
Dodge Magnum:
4-speed automatic (42RLE) for 2.7L V6; 5-speed automatic (W5A580) for 3.5L V6, 5.7L HEMI, 6.1L HEMI
Optional
All-Wheel-Drive:
Available on some 3.5L V6 and 5.7L HEMI models (Chrysler 300/300C)
Features
Transmission Fluid Type:
Chrysler ATF+4 (or equivalent specification for W5A580 and 42RLE)
📐 Dimensions
Exterior
Chrysler 300 Wheelbase:
Approx. 120 inches
Dodge Magnum Wheelbase:
Approx. 120 inches
Chrysler 300 Length:
Approx. 196.8 inches
Dodge Magnum Length:
Approx. 199.1 inches
Interior
Passenger Volume:
Over 100 cubic feet (class-leading for many years)
Cargo
Dodge Magnum Cargo Volume:
Approx. 20.2 - 71.6 cubic feet (seats up/down)
Weights
Curb Weight Range:
Approx. 3,800 - 4,300 lbs depending on engine and configuration
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Rating:
5-Star (for driver and front passenger in most configurations)
IIHS Side Impact Rating:
Good (for most models)
Active Features
Braking:
Four-wheel disc brakes with ABS standard
Traction Control:
Traction Control System (TCS) standard
Stability Control:
Electronic Stability Program (ESP/ESC) available or standard on later models
Passive Features
Airbags:
Frontal airbags, side curtain airbags, front seat-mounted side airbags
Seatbelts:
Three-point seat belts with pretensioners
💡 Technology Features
Infotainment
Available Systems:
Boston Acoustics or Infinity premium audio systems, Uconnect infotainment system with navigation (optional on later models).
Driver Assistance
Available Features:
ParkSense parking assist, Rain-sensing wipers, HID headlamps (optional on some trims).
Connectivity
Available Features:
Bluetooth hands-free communication via Uconnect system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 to 7,500 miles or 6 months, depending on driving conditions (consult owner's manual for specifics).
Transmission Fluid Service:
Check manual, often around 60,000-100,000 miles for replacement/flushing.
Fluid Specifications
Engine Oil Viscosity:
5W-20 (2.7L, 3.5L V6), 5W-20 or 5W-30 (5.7L HEMI, 6.1L HEMI - consult manual for exact specs)
Coolant Type:
OAT (Orange) HOAT coolant, Mopar specifications
Brake Fluid Type:
DOT 3
Known Issues
Chrysler 300/Dodge Magnum:
Early models had some reports of transmission issues (especially 42RLE), power steering pump leaks, and front suspension components. HEMI engines can be sensitive to oil viscosity.
Body Specific:
Rust on lower body panels and wheel arches, especially in corrosive climates; door lock actuator failures; window regulator issues.
📚 Vehicle History
Brand Heritage
Chrysler:
Long history of producing large, comfortable, and stylish American sedans.
Dodge:
Known for performance-oriented vehicles, the Magnum brought a unique, muscular wagon presence.
Model Evolution
Chrysler 300 (2005-2010):
Introduced as a revolutionary design revival, heavily inspired by the classic 1955 Chrysler C-300. Significant updates in 2008.
Dodge Magnum (2005-2008):
Based on the same LX platform as the Chrysler 300, offering a more practical wagon variant with bold styling. Discontinued after 2008.
Production
Manufacturing Location:
Brampton Assembly Plant, Ontario, Canada
🏆 Awards & Recognition
Recognitions
Chrysler 300:
Numerous automotive press awards including MotorTrend Car of the Year (2005), Car and Driver 10Best (2005-2006).
Dodge Magnum:
While not as decorated as the 300, it received recognition for its unique styling and performance (especially SRT8 models).
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