Dodge Charger 2007 Listing: 2005 Chrysler 300 & Dodge Magnum Service Manual

This DaimlerChrysler factory service manual covers the 2005 LX platform, including Chrysler 300, 300 Touring, 300C, and Dodge Magnum SE, SXT, and RT applications. It addresses the 2.7L DOHC V6, 3.5L High Output V6, and 5.7L HEMI V8, with RWD and AWD information. This is not the 2007 Dodge Charger publication, and it does not contain a separate 6.1L engine overhaul chapter.

PDF Search, Bookmarks, and Wiring Detail

Search and diagram access: Service text is searchable, but many wiring-diagram pages have no searchable text. Embedded bookmarks cover the service groups and component sections; three introductory entries point to separate files outside this download. Small labels on dense wiring pages require zooming for comfortable reading.

The download contains one printable English 7,289-page PDF. That total includes the group locator, 35 blank divider pages, three component-index pages, 12 DTC-index pages, and two service-comment/mailing pages.

LX Powertrain, Chassis, and Electrical Service

The following selected coverage highlights outline the repair content. Additional topics include tire-and-wheel vibration diagnosis and wiper/washer service.

• Engine repair: Step-by-step engine removal and installation, internal component repair, lubrication-system work, and engine-specific timing-chain or timing-belt procedures.

• Transmission and driveline: 42RLE and NAG1 electrical diagnosis, unit removal, internal disassembly and reassembly, clutch service, propeller shafts, rear half shafts, and differential repair.

• Suspension and steering: Front and rear hubs, ball joints, control arms, tension struts, shocks, springs, steering gear and column, curb-height measurement, and four-wheel alignment.

• Brakes and stability control: Calipers, pads, rotors, master cylinder, booster, parking brake, ABS/ESP fault isolation, bleeding, sensor calibration, and verification tests.

• Electrical troubleshooting: DTC-based circuit tests, module communication diagnosis, wiring schematics, connector pinouts, and connector, ground, and splice-location information.

• Body and restraints: Doors, glass and regulators, seats, instrument panel, liftgate, decklid, sunroof, airbags, occupant-classification hardware, and body-structure reference drawings.

• Climate control: Refrigerant recovery, evacuation and charging, performance and leak tests, compressor and condenser service, evaporator and heater-core work, and door-actuator diagnosis.

This manual is suited to technicians and experienced repairers familiar with scan-tool diagnosis and equipped for internal engine and automatic-transmission work.

Engine Diagnosis, Timing, and Supporting Systems

Compression and cylinder-leakage diagnosis accompany cylinder-head disassembly, valve and guide inspection, camshaft and bearing checks, crankshaft and piston/connecting-rod service, oil-pump work, and intake and exhaust component repair. The 5.7L section also covers Multi-Displacement System (MDS) components and diagnostics.

The timing sections distinguish 2.7L timing-chain and 3.5L timing-belt procedures. The 2.7L chapter warns that incorrect crankshaft or camshaft positioning with the chain removed can damage valves or pistons.

Factory tool references include Engine Lifting Fixture 8342 and Timing Chain Tensioner Resetting Gauge 8186.

Cooling, fuel, and maintenance: Cooling-system pressure and leak testing, thermostat checks, water-pump service, fuel-pressure diagnosis, pump-module replacement, and evaporative-emissions information extend the coverage beyond engine teardown. Maintenance schedules distinguish sedan, wagon, and export applications; identification information includes United States, Canadian, Mexican, and international market codes.

Transmission Overhaul and Rear-Axle Setup

The 42RLE material explains adaptive electronic control, hydraulic pressure tests, clutch clearances, solenoid/pressure-switch operation, pump and valve-body work, accumulators, geartrain, and torque-converter service.

NAG1 coverage addresses its three planetary sets, B-series holding clutches, K-series input clutches, electrohydraulic control unit, shift mechanism, and torque converter. End-play measurement uses End Play Set 8266; scan-tool TCM adaptation is specified after transmission reconditioning or replacement.

For the 198RII and 210RII rear axles, noise and vibration diagnosis leads into pinion-depth setup, bearing preload, ring-gear backlash, tooth-contact checks, and differential disassembly.

Chassis Details and Repair Cautions

Rear-suspension procedures distinguish standard shocks from Nivomat load-leveling units and identify AWD crossmember spacers and different front/rear mounting bolts. Front-suspension tool references include Puller 9360.

The alignment section warns that rotating the special grooved control-arm or tension-strut bolts during removal or installation can damage the bushing or cradle. Their orientation also determines the camber or caster correction.

Circuit Tracing and Module Diagnosis

Wiring references: 8W-10 Power Distribution, 8W-18 Bus Communications, and 8W-35 Antilock Brakes provide system schematics. Further references include 8W-43 Occupant Restraint System, 8W-80 Connector Pin-Outs, and 8W-91 Connector/Ground/Splice Location.

Connector, ground, and splice-location information supports component-to-component circuit tracing. Combined with fault-code tests, it supports diagnosis across PCM/TCM functions, the Integrated Power Module, CAN communication, ABS/ESP, ORC and Occupant Classification Module circuits, lighting, heated systems, power accessories, navigation/audio, and theft security.

Body Structure, HVAC Controls, and Safe Service

Sedan- and wagon-specific body references include panel gap and flush, opening dimensions, sealer maps, structural-adhesive drawings, and weld-location views. HVAC diagnosis distinguishes manual temperature control from automatic temperature control; the manual system is not addressable with a scan tool.

Component-specific torque tables, fluid capacities, wear limits, pressure-test data, alignment specifications, and electrical test values appear within their applicable groups, with metric and SAE units.

Before suspension, drivetrain, brake, restraint, or refrigerant-system repair, the vehicle must be supported at the specified lift points and the applicable isolation and safety procedures must be followed. Airbag circuits, compressed springs, fuel systems, and A/C refrigerant require the equipment and training identified in the factory information.

A Preview of Transmission End-Play Specifications

NAG1 assembly: The input-shaft end-play specification after assembly is 0.3–0.5 mm (0.012–0.020 in.), with selective-shim adjustment covered in the assembly section.

42RLE inspection: Its input-shaft end-play specification is 0.127–0.635 mm (0.005–0.025 in.). The separate transmission sections provide the corresponding measurement procedures and assembly context.