CHRYSLER CROSSFIRE Service Repair Manual 2004-2008
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🏷️ Basic Information Identification Make: Chrysler Model: Crossfire Years Covered: 2004-2008 Codes Chassis Code: ZH 👋 Introduction Market Position Segment: Compact Sports Car / Roadster Unique Selling Proposition: Unique European design influence (based on Mercedes-Benz R170 SLK platform), rear-wheel drive performance, distinctive styling Competitive Analysis Key Competitors: Mazda MX-5 Miata, BMW Z4, Honda S2000, Nissan 350Z Roadster, Porsche Boxster Key Features Body Styles: Roadster (2-seater convertible), Coupe (2-seater hardtop) Platform Sharing: Developed in collaboration with DaimlerChrysler, utilizing components from the Mercedes-Benz SLK platform 📋 Manual Details Coverage Areas All Repair Topics: A-Z Model Coverage: All Models Page Count Estimated Page Count: Extensive (Typically 2000+ pages for full workshop manuals) Manual Type Type: Service and Repair Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, emissions control, engine management (ECU) Transmission: Automatic transmission (5-speed NAG1/W5A580), clutch (manual), gearbox, driveline, differentials Brakes: Hydraulic system, ABS, EBD, brake calipers, rotors, pads, parking brake, fluid specifications Suspension: Front suspension (double wishbone), rear suspension (multi-link), springs, shock absorbers, steering knuckles, wheel bearings Steering: Power steering system, steering column, steering rack/box, linkages, wheel alignment specifications Electrical: Battery, charging system, starter, lighting, wipers, horn, power accessories, interior/exterior electrical components, wiring diagrams, fuses, relays Body And Chassis: Body structure, exterior panels, doors, hood, trunk, bumpers, interior trim, seats, glass, weatherstripping, rust proofing HVAC: Heating, ventilation, air conditioning system, refrigerant, components (compressor, condenser, evaporator), diagnostics Infotainment And Comfort: Audio system, navigation, climate control interfaces, power seats, power windows, central locking Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, diagnostic trouble codes (DTCs) Repair: Detailed step-by-step instructions for component removal, installation, and repair for all major systems Overhaul: Engine and transmission overhaul procedures, including disassembly, inspection, and reassembly Wiring And Diagnostics: Comprehensive wiring diagrams, component location charts, diagnostic connector information, scan tool usage Technical Depth Depth: Full workshop level, covering everything from basic maintenance to complete engine and transmission rebuilds, advanced diagnostics, and body repair 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable text, bookmark navigation Print Quality Printable: Yes, designed for printing specific sections or the entire manual Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code: M111 E23 ML (Supercharged) Engine Type: Inline 4-cylinder, DOHC, 16-valve with Supercharger Displacement: 2.3 Liters (2295 cc) Performance Horsepower: 190 hp @ 5300 rpm (standard), 215 hp @ 5100 rpm (SRT-6) Torque: 200 lb-ft @ 2500 rpm (standard), 229 lb-ft @ 3500 rpm (SRT-6) Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) with Supercharger Fuel Type: Premium Unleaded Gasoline (91 Octane or higher recommended) Other Bore X Stroke: 89.9 mm x 92.4 mm Compression Ratio: 8.8:1 Engine Management: Bosch Motronic ME 2.8 🔧 Transmission Standard Standard Transmission: 6-speed Manual (Getrag) Optional Optional Transmission: 5-speed Automatic (Mercedes-Benz NAG1 / W5A580) Features Automatic Features: TouchShift (manual shifting mode) Manual Features: Hydraulic clutch actuation Fluids Automatic Transmission Fluid Spec: MB-Approval 236.10 (e.g., Pentosin ATF1) Manual Transmission Fluid Spec: GL-4, SAE 75W-85 📐 Dimensions Exterior Length: 169.2 inches (4300 mm) Width: 69.5 inches (1765 mm) Height: 50.6 inches (1285 mm) Wheelbase: 94.7 inches (2405 mm) Cargo Cargo Volume Trunk Roadster: Approx. 7.4 cu ft (210 L) with top up Cargo Volume Trunk Coupe: Approx. 10.6 cu ft (300 L) Weights Curb Weight Roadster: Approx. 3075 lbs (1395 kg) Curb Weight Coupe: Approx. 3108 lbs (1410 kg) Wheels And Tires Wheel Size: 17-inch front, 18-inch rear (standard) Tire Size Front: 225/40R17 Tire Size Rear: 255/35R18 Wheel Bolt Pattern: 5x112 🛡️ Safety Features Ratings NHTSA Front Crash Rating: 4-star driver, 4-star passenger (2005 model) IIHS Crash Test Rating: Good (Frontal Offset) - 2005 model Active Features ABS: Standard Anti-lock Braking System Esp: Standard Electronic Stability Program (ESP) Traction Control: Standard Traction Control System (TCS) Passive Features Airbags: Driver and passenger front airbags, side-impact airbags Rollover Protection: Automatic deploying rollover protection bars (Roadster) 💡 Technology Features Infotainment Audio System: Premium Boston Acoustics sound system (optional), AM/FM/CD player, optional navigation system. Navigation: Optional factory navigation system integrated into the dashboard. Driver Assistance Cruise Control: Standard cruise control. Connectivity Auxiliary Input: Limited (typically no standard AUX or USB ports on early models, aftermarket solutions available). 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles (12,000 km) or 12 months, whichever comes first (using synthetic oil) Air Filter Replacement Interval: Every 15,000 miles (24,000 km) Cabin Air Filter Replacement Interval: Every 15,000 miles (24,000 km) or annually Spark Plug Replacement Interval: Every 100,000 miles (160,000 km) (Long-life iridium plugs) Brake Fluid Flush Interval: Every 2 years or 24,000 miles (38,000 km) Fluid Specifications Engine Oil Type: SAE 0W-30 Full Synthetic (Meets MB-Approval 229.5)...
Premium Boston Acoustics sound system (optional), AM/FM/CD player, optional navigation system.
Navigation:
Optional factory navigation system integrated into the dashboard.
Driver Assistance
Cruise Control:
Standard cruise control.
Connectivity
Auxiliary Input:
Limited (typically no standard AUX or USB ports on early models, aftermarket solutions available).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 12 months, whichever comes first (using synthetic oil)
Air Filter Replacement Interval:
Every 15,000 miles (24,000 km)
Cabin Air Filter Replacement Interval:
Every 15,000 miles (24,000 km) or annually
Spark Plug Replacement Interval:
Every 100,000 miles (160,000 km) (Long-life iridium plugs)
Brake Fluid Flush Interval:
Every 2 years or 24,000 miles (38,000 km)
Fluid Specifications
Engine Oil Type:
SAE 0W-30 Full Synthetic (Meets MB-Approval 229.5)
Coolant Type:
Glysantin G05 (HOAT) or equivalent blue/green antifreeze, mixed 50/50 with distilled water
Power Steering Fluid Type:
MB-Approval 236.3 (e.g., Pentosin CHF 11S)
Brake Fluid Type:
DOT 4 (Meets MB-Approval 331.0)
Known Issues
Common Issues Electrical:
Water ingress affecting electronics (especially ABS module), intermittent warning lights, power window/lock failures.
Common Issues Mechanical:
Supercharger belt tensioner issues, oil cooler leaks, some reports of camshaft solenoid failures.
Common Issues Interior:
Seat bolster wear, trim piece creaks or rattles, convertible top mechanism maintenance.
📚 Vehicle History
Brand Heritage
Manufacturer Heritage:
Chrysler's history includes pioneering automotive design and engineering, with a focus on performance and style, especially in its sports car offerings.
Model Evolution
First Generation:
Introduced for the 2004 model year, the Crossfire was designed by Eric Stoddard at Chrysler and developed in collaboration with DaimlerChrysler, leveraging the chassis and many components from the Mercedes-Benz R170 SLK.
Facelift And Updates:
Minor updates and feature additions occurred throughout its production run. The SRT-6 variant, with its supercharged engine and sport-tuned suspension, was introduced in 2005.
Production
Production Period:
2003 (as a concept), 2004-2008
Manufacturing Location:
Karmann factory in Osnabrück, Germany
🏆 Awards & Recognition
Recognitions
Design Awards:
Recognized for its distinctive styling, often praised for its unique blend of American and European design influences.
Ratings
Consumer Reports Reliability:
Varies by year and specific component; often average to below average in its early years, with specific notes on electrical system reliability.
Certifications
Emissions Standards:
Meets relevant US EPA and CARB emissions standards for the model years produced.
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