Chrysler 300M 2004 Service Repair Workshop Manual

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Basic Information Identification Make: Chrysler Model: 300M Year: 2004 Codes Chassis Code: LH Engine Code: EGG (3.5L) Introduction Market Position Vehicle Segment: Full-size sedan, marketed as a premium or near-luxury offering. Competitive Analysis Key Competitors: Ford Crown Victoria, Mercury Grand Marquis, Chevrolet Impala, Toyota Avalon, Buick LeSabre, Oldsmobile Aurora. Key Features Design Philosophy: Cab-forward design, aerodynamic styling, spacious interior, and comfortable ride. Target Audience: Buyers seeking a comfortable, stylish, and spacious sedan with American heritage. Value Proposition Manual Value: Provides professional-level repair and maintenance information, enabling owners to perform complex tasks, save on labor costs, and maintain their vehicle's optimal condition. Manual Details Coverage Areas Manual Type: Service Repair Workshop Manual Language: English Format: PDF Download Page Count Estimated Page Count: Over 2000 pages (typical for comprehensive service manuals of this era) Manual Type Manual Category: Factory Service Manual / Workshop Manual Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, troubleshooting, diagnostics, and specifications for the 3.5L V6 engine. Engine Performance: Fuel injection system, ignition system, emissions control systems, cooling system, lubrication system. Transmission Automatic: Service and repair procedures for the 42LE automatic transmission, including torque converter, valve body, solenoids, and electronic controls. Drivetrain: Front-wheel drive system, CV joints, driveshafts, differential components. Suspension: Front and rear suspension systems, struts, shock absorbers, control arms, ball joints, wheel bearings, and alignment procedures. Steering: Power steering system, steering gear, steering column, and related components. Brakes: Front and rear disc brakes, ABS (Anti-lock Braking System) components, hydraulic system, parking brake, and troubleshooting. Electrical System: Battery, charging system (alternator), starting system (starter motor), fuses, relays, wiring diagrams, and component testing. Lighting: Headlights, taillights, interior lighting, fog lights, and related electrical circuits. HVAC: Heating, ventilation, and air conditioning (HVAC) system, climate control, refrigerant handling, and component replacement. Body And Interior: Body panels, doors, windows, locks, seats, upholstery, dashboard, and trim components. Chassis Electrical: Instrument cluster, power windows, power locks, remote keyless entry, cruise control, and other chassis electrical systems. Safety Systems: Airbag system (SRS - Supplemental Restraint System) diagnosis and service, seat belts. Diagnostic Trouble Codes: Coverage of OBD-II diagnostic trouble codes (DTCs) and diagnostic procedures. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement, and belt inspections. Troubleshooting: Step-by-step diagnostic guides for common and complex issues across all vehicle systems. Component Repair: Detailed instructions for the removal, repair, and installation of virtually all mechanical and electrical components. Engine Rebuild: Complete engine overhaul procedures, including torque specifications, piston ring installation, valve adjustments, and cylinder head service. Transmission Overhaul: Detailed procedures for rebuilding the automatic transmission, including clutch pack replacement and valve body calibration. Brake Service: Brake pad and rotor replacement, brake caliper service, brake bleeding procedures, and ABS system component replacement. Electrical Diagnostics: Schematic reading, wiring harness testing, sensor testing, and module diagnosis. HVAC Service: Refrigerant evacuation and recharge, component replacement (compressor, condenser, evaporator), and leak testing. Body Panel Repair: Dent removal, panel replacement, and alignment procedures. Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic preventative maintenance to complete vehicle overhaul and advanced diagnostics. Diagnostic Level: Advanced, including detailed diagnostic flowcharts, sensor data interpretation, and module programming concepts. Repair Instructions: Detailed, step-by-step instructions with clear language and illustrations/diagrams for all repair procedures. Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely text-searchable if professionally scanned and OCR'd, allowing for quick information retrieval. Print Quality Print Quality Description: High-resolution scans suitable for printing individual pages or the entire manual. Binding Type Binding Type Description: Digital download (PDF), not physically bound. Paper Type Paper Type Description: N/A (Digital format) Engine Specifications Primary Engine Engine Type: Naturally Aspirated SOHC V6 Displacement: 3.5 Liters (3500 cc) Bore X Stroke: 96.0 mm x 81.0 mm (approximate) Compression Ratio: 9.3:1 Performance Horsepower: 255 hp @ 6400 rpm (SAE Net) Torque: 250 lb-ft @ 3950 rpm (SAE Net) Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline, 87 Octane (recommended) Engine Code Identifier Engine Code: EGG Transmission Standard Transmission Type: 4-Speed Automatic Transmission Model: 42LE Optional Optional Transmission: N/A (Only 4-speed automatic offered) Features Transmission Features: Electronic control, adaptive shift logic, driver-selectable overdrive. Fluid Specifications Transmission Fluid Type: ATF+4 (Automatic Transmission Fluid Type 9602) Fluid Capacity Transmission Fluid Capacity: Approx. 9.5 quarts (9.0 liters) for a dry fill. Dimensions Exterior Length: 199.4 inches (5065 mm) Width: 74.4 inches (1890 mm) Height: 57.0 inches (1448 mm) Wheelbase: 112.1 inches (2847 mm) Front Track: 62.4 inches (1585 mm) Rear Track: 61.8 inches (1570 mm) Weights Curb Weight: Approx. 3650 - 3750 lbs (1655 - 1700 kg) Gross Vehicle Weight Rating: Approx. 4750 lbs (2154 kg) Cargo Cargo Volume: 16.0 cubic feet (453 liters) Interior Passenger Volume: 104.3 cubic feet (2953 liters) Safety Features Ratings NHTSA Front Impact Driver: 5 Stars (2004 Model Year) NHTSA Front Impact Passenger:...

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Description

Basic Information
Identification
Make:	Chrysler
Model:	300M
Year:	2004
Codes
Chassis Code:	LH
Engine Code:	EGG (3.5L)

Introduction
Market Position
Vehicle Segment:	Full-size sedan, marketed as a premium or near-luxury offering.
Competitive Analysis
Key Competitors:	Ford Crown Victoria, Mercury Grand Marquis, Chevrolet Impala, Toyota Avalon, Buick LeSabre, Oldsmobile Aurora.
Key Features
Design Philosophy:	Cab-forward design, aerodynamic styling, spacious interior, and comfortable ride.
Target Audience:	Buyers seeking a comfortable, stylish, and spacious sedan with American heritage.
Value Proposition
Manual Value:	Provides professional-level repair and maintenance information, enabling owners to perform complex tasks, save on labor costs, and maintain their vehicle's optimal condition.

Manual Details
Coverage Areas
Manual Type:	Service Repair Workshop Manual
Language:	English
Format:	PDF Download
Page Count
Estimated Page Count:	Over 2000 pages (typical for comprehensive service manuals of this era)
Manual Type
Manual Category:	Factory Service Manual / Workshop Manual

Manual Coverage
Systems Covered
Engine Mechanical:	Complete engine disassembly, assembly, troubleshooting, diagnostics, and specifications for the 3.5L V6 engine.
Engine Performance:	Fuel injection system, ignition system, emissions control systems, cooling system, lubrication system.
Transmission Automatic:	Service and repair procedures for the 42LE automatic transmission, including torque converter, valve body, solenoids, and electronic controls.
Drivetrain:	Front-wheel drive system, CV joints, driveshafts, differential components.
Suspension:	Front and rear suspension systems, struts, shock absorbers, control arms, ball joints, wheel bearings, and alignment procedures.
Steering:	Power steering system, steering gear, steering column, and related components.
Brakes:	Front and rear disc brakes, ABS (Anti-lock Braking System) components, hydraulic system, parking brake, and troubleshooting.
Electrical System:	Battery, charging system (alternator), starting system (starter motor), fuses, relays, wiring diagrams, and component testing.
Lighting:	Headlights, taillights, interior lighting, fog lights, and related electrical circuits.
HVAC:	Heating, ventilation, and air conditioning (HVAC) system, climate control, refrigerant handling, and component replacement.
Body And Interior:	Body panels, doors, windows, locks, seats, upholstery, dashboard, and trim components.
Chassis Electrical:	Instrument cluster, power windows, power locks, remote keyless entry, cruise control, and other chassis electrical systems.
Safety Systems:	Airbag system (SRS - Supplemental Restraint System) diagnosis and service, seat belts.
Diagnostic Trouble Codes:	Coverage of OBD-II diagnostic trouble codes (DTCs) and diagnostic procedures.
Procedures Included
Routine Maintenance:	Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement, and belt inspections.
Troubleshooting:	Step-by-step diagnostic guides for common and complex issues across all vehicle systems.
Component Repair:	Detailed instructions for the removal, repair, and installation of virtually all mechanical and electrical components.
Engine Rebuild:	Complete engine overhaul procedures, including torque specifications, piston ring installation, valve adjustments, and cylinder head service.
Transmission Overhaul:	Detailed procedures for rebuilding the automatic transmission, including clutch pack replacement and valve body calibration.
Brake Service:	Brake pad and rotor replacement, brake caliper service, brake bleeding procedures, and ABS system component replacement.
Electrical Diagnostics:	Schematic reading, wiring harness testing, sensor testing, and module diagnosis.
HVAC Service:	Refrigerant evacuation and recharge, component replacement (compressor, condenser, evaporator), and leak testing.
Body Panel Repair:	Dent removal, panel replacement, and alignment procedures.
Technical Depth
Depth Of Coverage:	Comprehensive, covering everything from basic preventative maintenance to complete vehicle overhaul and advanced diagnostics.
Diagnostic Level:	Advanced, including detailed diagnostic flowcharts, sensor data interpretation, and module programming concepts.
Repair Instructions:	Detailed, step-by-step instructions with clear language and illustrations/diagrams for all repair procedures.

Manual Specifications
File Format
File Type:	PDF (Portable Document Format)
Searchability:	Likely text-searchable if professionally scanned and OCR'd, allowing for quick information retrieval.
Print Quality
Print Quality Description:	High-resolution scans suitable for printing individual pages or the entire manual.
Binding Type
Binding Type Description:	Digital download (PDF), not physically bound.
Paper Type
Paper Type Description:	N/A (Digital format)

Engine Specifications
Primary Engine
Engine Type:	Naturally Aspirated SOHC V6
Displacement:	3.5 Liters (3500 cc)
Bore X Stroke:	96.0 mm x 81.0 mm (approximate)
Compression Ratio:	9.3:1
Performance
Horsepower:	255 hp @ 6400 rpm (SAE Net)
Torque:	250 lb-ft @ 3950 rpm (SAE Net)
Fuel System
Fuel Delivery:	Multi-port Fuel Injection (MPI)
Fuel Type:	Unleaded Gasoline, 87 Octane (recommended)
Engine Code Identifier
Engine Code:	EGG

Transmission
Standard
Transmission Type:	4-Speed Automatic
Transmission Model:	42LE
Optional
Optional Transmission:	N/A (Only 4-speed automatic offered)
Features
Transmission Features:	Electronic control, adaptive shift logic, driver-selectable overdrive.
Fluid Specifications
Transmission Fluid Type:	ATF+4 (Automatic Transmission Fluid Type 9602)
Fluid Capacity
Transmission Fluid Capacity:	Approx. 9.5 quarts (9.0 liters) for a dry fill.

Dimensions
Exterior
Length:	199.4 inches (5065 mm)
Width:	74.4 inches (1890 mm)
Height:	57.0 inches (1448 mm)
Wheelbase:	112.1 inches (2847 mm)
Front Track:	62.4 inches (1585 mm)
Rear Track:	61.8 inches (1570 mm)
Weights
Curb Weight:	Approx. 3650 - 3750 lbs (1655 - 1700 kg)
Gross Vehicle Weight Rating:	Approx. 4750 lbs (2154 kg)
Cargo
Cargo Volume:	16.0 cubic feet (453 liters)
Interior
Passenger Volume:	104.3 cubic feet (2953 liters)

Safety Features
Ratings
NHTSA Front Impact Driver:	5 Stars (2004 Model Year)
NHTSA Front Impact Passenger:	5 Stars (2004 Model Year)
IIHS Frontal Offset:	Good (2004 Model Year)
Active Features
ABS:	Standard (4-wheel disc brakes with ABS)
Traction Control:	Optional (Traction Control System - TCS)
Passive Features
Airbags:	Standard: Advanced front airbags (driver and passenger). Optional: Side curtain airbags.
Seat Belts:	3-point seat belts with pretensioners for front occupants, 3-point seat belts for rear occupants.
Child Seat Anchors:	LATCH (Lower Anchors and Tethers for CHildren) system.

Technology Features
Infotainment
Infotainment System:	Optional Infinity II audio system with CD player and cassette deck. Some models may have had optional navigation systems.
Speaker Configuration:	Available with 6 or 8 speakers (Infinity system).
Driver Assistance
Cruise Control:	Standard cruise control.
Parking Assist:	N/A (No factory parking sensors or backup cameras for this model year)
Connectivity
Connectivity Features:	Keyless entry system, power accessories (windows, locks, mirrors).

Maintenance
Service Intervals
Oil Change Interval:	Every 7,500 miles (12,000 km) or 6 months, whichever comes first, under normal driving conditions. Severe driving conditions may require more frequent changes (e.g., 3,750 miles).
Air Filter Replacement:	Inspect every 15,000 miles (24,000 km), replace as needed. Recommended replacement every 30,000 miles (48,000 km).
Spark Plug Replacement:	Platinum-tipped spark plugs typically rated for 100,000 miles (160,000 km) replacement interval. Refer to manual for specific plug type and gap.
Transmission Fluid Change:	Recommended every 30,000 - 60,000 miles (48,000 - 96,000 km) depending on driving conditions. Crucial for longevity of the 42LE transmission.
Fluid Specifications
Engine Oil Type:	SAE 5W-30 Synthetic Blend or Full Synthetic (API Certified)
Engine Oil Capacity:	Approx. 5 quarts (4.7 liters) with filter change.
Coolant Type:	Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, extended life (e.g., Mopar P52551323AA or equivalent).
Brake Fluid Type:	DOT 3 (or DOT 4 if specified for ABS systems)
Known Issues
Common Issues Engine:	Minor oil leaks from valve cover gaskets, intake manifold gaskets, and PCV valve. Occasional issues with crankshaft position sensor failing, leading to stalling. Spark plug blow-out on earlier models (less common on 2004).
Common Issues Transmission:	The 42LE transmission can be sensitive to heat and fluid degradation. Overheating and harsh shifting can indicate internal wear or solenoid issues. Regular fluid and filter changes are critical.
Common Issues Suspension:	Worn control arm bushings, ball joints, and tie rod ends due to vehicle weight and mileage. Premature wear of front struts/shocks.
Common Issues Electrical:	Problems with power window regulators and motors, door lock actuators, and HVAC blower motor resistor. Climate control head unit failures can occur.
Common Issues Body:	Paint peeling on the roof and hood, particularly on lighter colors. Door seal degradation leading to wind noise.

Vehicle History
Brand Heritage
Brand History Context:	Chrysler, a long-standing American automotive manufacturer, known for its focus on styling and comfort in sedans.
Model Evolution
Model Lineage:	The 300M was part of Chrysler's LH platform cars, which debuted in the early 1990s. It represented an evolution of the premium sedan offerings, succeeding models like the Chrysler Concorde and LHS, while sharing its platform with the Dodge Intrepid and Chrysler Concorde.
Production
Production Years:	1999-2004
Manufacturing Location:	Brampton Assembly Plant, Brampton, Ontario, Canada
Model Updates
2004 Model Year Changes:	Minor enhancements to features and trim, building on the established platform and powertrain.

Awards & Recognition
Recognitions
Car And Driver 10 Best:	Named to Car and Driver's 10Best list for 1999 and 2000.
Motor Trend Car Of The Year:	N/A (Competed for MotorTrend Car of the Year, but did not win in its debut year).
Ratings
Consumer Reports Ratings:	Consumer Reports ratings for this model year varied, with some praise for comfort and performance but concerns regarding reliability in certain areas, particularly transmission and electrical components.
Certifications
Certification Type:	N/A (No specific industry certifications beyond standard automotive manufacturing practices)