2004 Chrysler Crossfire Service & Repair Manual

GROUP TAB LOCATOR Introduction 0 Lubrication & Maintenance 2 Suspension 3 Differential & Driveline 5 Brakes 6 Clutch 7 Cooling 8A Audio/Video 8B Chime/Buzzer 8E Electronic Control Modules 8F Engine Systems 8G Heated Systems 8H Horn 8I Ignition Control 8J Instrument Cluster 8L Lamps 8M Message Center 8N Power Systems 8O Restraints 8P Speed Control 8Q Vehicle Theft Security 8R Wipers/Washers 8W Wiring 9 Engine 11 Exhaust System 13 Frame & Bumpers 14 Fuel System 19 Steering 21 Transmission/Transaxle 22 Tires/Wheels 23 Body 24 Heating & Air Conditioning 25 Emissions Control Component and System Index PCODE Index Service Manual Comment Forms (Rear of Manual)

INTRODUCTION TABLE OF CONTENTS page page VEHICLE SAFETY CERT LABEL DESCRIPTION .......................... 1 VEHICLE IDENTIFICATION NUMBER DESCRIPTION .......................... 2 INTERNATIONAL SYMBOLS DESCRIPTION .......................... 2 FASTENER IDENTIFICATION DESCRIPTION .......................... 3 FASTENER USAGE DESCRIPTION FASTENER USAGE ..................... 6 THREADED HOLE REPAIR ............... 6 METRIC SYSTEM DESCRIPTION .......................... 6 TORQUE REFERENCES DESCRIPTION .......................... 8 VECI LABEL DESCRIPTION .......................... 9 VEHICLE SAFETY CERT LABEL DESCRIPTION A vehicle safety certification label is attached to the rear shut- face of the driver’s door. This label indicates date of manufacture (month and year), Gross Vehicle Weight Rating (GVWR), Gross Axle Weight Rating (GAWR) front, Gross Axle Weight Rating (GAWR) rear and the Vehicle Identification Number (VIN). The Month, Day and Hour of manufacture is also included. All communications or inquiries regarding the vehicle should include the Month-Day-Hour and Vehicle Identification Number. ZH INTRODUCTION 1

VEHICLE IDENTIFICATION NUMBER DESCRIPTION The Vehicle Identification Number (VIN) is located on the upper left corner of the dash panel, inside the windshield opening. The VIN consists of 17 characters in a combination of letters and numbers that provide specific information about the vehicle. Refer to VIN Code Breakdown table for decoding information. CROSSFIRE VIN CODE BREAKDOWN POSITION INTERPRETATION CODE = DESCRIPTION 1 Country of Origin 1 = Manufactured By DaimlerChrysler Corporation 2 Make C = Chrysler 3 Vehicle Type 3 = Passenger Car 4 Other K = Restraint System Front Air Bags Next Generation (CGW) With Standard Side Air Bag Supplement (CGS) 5 Car Line N = Crossfire (LHD) P = Crossfire (RHD) 6 Series 6 = “S” Series 6 - Export Transmission C = 6 Speed Manual (DED) E = 5 Speed Automatic (DGU) 7 Body Style 9 = Specialty Coupe 8 Engines L = 3.2L V6 SOHC 18 Valve 9 Check Digit See explanation in this section 10 Model Year 4 = Model Year 11 Plant X = Osnabrueck Germany 12 through 17 Sequence Number 6 Digit Sequential Number Assigned By Assembly Plant. INTERNATIONAL SYMBOLS DESCRIPTION The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel. 2 INTRODUCTION ZH

FASTENER IDENTIFICATION DESCRIPTION The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts. 1 HIGH BEAM 13 REAR WINDOW WASHER 2 FOG LAMPS 14 FUEL 3 HEADLAMP, PARKING LAMPS, PANELLAMPS 15 ENGINE COOLANT TEMPERATURE 4 TURN WARNING 16 BATTERY CHARGING CONDITION 5 HAZARD WARNING 17 ENGINE OIL 6 WINDSHIELD WASHER 18 SEAT BELT 7 WINDSHIELD WIPER 19 BRAKE FAILURE 8 WINDSHIELD WIPER AND WASHER 20 PARKING BRAKE 9 WINDSCREEN DEMISTING AND DEFROSTING 21 FRONT HOOD 10 VENTILATING FAN 22 REAR HOOD (DECKLID) 11 REAR WINDOW DEFOGGER 23 HORN 12 REAR WINDOW WIPER 24 LIGHTER ZH INTRODUCTION 3 FASTENER IDENTIFICATION (Continued)

4 INTRODUCTION ZH FASTENER IDENTIFICATION (Continued)

ZH INTRODUCTION 5 FASTENER IDENTIFICATION (Continued)

FASTENER USAGE DESCRIPTION FASTENER USAGE WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PERSONAL INJURY. Fasteners and torque specifications references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassem- bly. If the fastener is not salvageable, a fastener of equivalent specification must be used. THREADED HOLE REPAIR Most stripped threaded holes can be repaired using a HelicoilT. Follow the vehicle or HelicoilT recommendations for application and repair procedures. METRIC SYSTEM DESCRIPTION The metric system is based on quantities of one, ten, one hundred, one thousand and one million. The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa. CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY BY TO GET MULTIPLY BY TO GET in-lbs x 0.11298 = Newton Meters (N·m) N·m x 8.851 = in-lbs ft-lbs x 1.3558 = Newton Meters (N·m) N·m x 0.7376 = ft-lbs Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches Feet x 0.3048 = Meters (M) M x 3.281 = Feet Yards x 0.9144 = Meters M x 1.0936 = Yards mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph Kilometers/Hr. (Km/h) x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h) COMMON METRIC EQUIVALENTS 1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters 1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter 1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter 1 Mile = 1.6 Kilometers 6 INTRODUCTION ZH

Refer to the Metric Conversion Chart to convert torque values listed in metric Newton- meters (N·m). Also, use the chart to convert between millimeters (mm) and inches (in.). ZH INTRODUCTION 7 METRIC SYSTEM (Continued)

TORQUE REFERENCES DESCRIPTION Individual torque charts appear within many of the groups. Refer to the Standard Torque Specifications Chart for torque references not listed in the individual torque charts. 8 INTRODUCTION ZH

VECI LABEL DESCRIPTION All models have a Vehicle Emission Control Information (VECI) Label. Chrysler permanently attaches the label in the engine compartment. It cannot be removed without defacing information and destroying the label. The label contains the vehicle’s emission specifications and vac- uum hose routings. All hoses must be connected and routed according to the label. ZH INTRODUCTION 9

2004 Chrysler Crossfire Service & Repair Manual

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