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Engine Cooling System & Automatic Transmission Cooling System: Removal & Installation Chrysler Crossfire I

Accessory Drive Belts 14 illustrations ~3092 words

INSTALLATION

  1. Lubricate the new coolant level sensor o-ring with coolant.
  2. Push the coolant level sensor (1) into the coolant recovery reservoir until it snaps into place.
  3. Connect the coolant level sensor harness connector (2).
  4. Refill the cooling system. «(Refer to COOLING/ENGINE/COOLANT - STANDARD PROCEDURE)»(ref-250623-S38251009092007031500000) .
  5. Start the engine and check for coolant leaks.
  6. Recheck the coolant level and adjust as necessary.
  1. Install the thermostat housing with a new O-ring. Tighten the bolts to 10 N.m (89 in. lbs.).
  2. Connect the upper radiator hose.
  3. Fill the cooling system. «(Refer to COOLING/ENGINE/COOLANT - STANDARD PROCEDURE)»(ref-250623-S38251009092007031500000) .
  4. Start the engine and check for coolant leaks.
  5. Recheck the coolant level and adjust as necessary.
  1. Position the coolant recovery reservoir in the engine compartment.
  2. Install the two retaining nuts (2). Tighten the nuts to 5 N.m (44 in. lbs.).
  3. Connect the coolant overflow hose (1).
  4. Connect the coolant level sensor harness connector (2).
  5. Connect the small coolant hose (4) from the radiator to the top of the coolant recovery reservoir.
  6. Connect the large coolant hose (3) to the bottom of the coolant recovery reservoir.
  7. Refill the cooling system. «(Refer to COOLING/ENGINE/COOLANT - STANDARD PROCEDURE)»(ref-250623-S38251009092007031500000) .
  8. Connect the negative battery cable.
  9. Start the engine and check for coolant leaks.
  10. Recheck the coolant level.

INSTALLATION - SRT

  1. Position the coolant recovery reservoir in the engine compartment.
  2. Install the two retaining nuts (2). Tighten the nuts to 5 N.m (44 in. lbs.).
  3. Connect the coolant overflow hose (1).
  4. Connect the coolant level sensor harness connector (2).
  5. Connect the small coolant hose (4) from the radiator to the top of the coolant recovery reservoir.
  6. Connect the large coolant hose (3) to the bottom of the coolant recovery reservoir.
  7. Connect the charge air cooler coolant hose (2) to the bottom of the coolant recovery reservoir (1).
  8. Refill the cooling system. «(Refer to COOLING/ENGINE/COOLANT - STANDARD PROCEDURE)»(ref-250623-S38251009092007031500000) .
  9. Connect the negative battery cable.
  10. Start the engine and check for coolant leaks.
  11. Recheck the coolant level.

Scheme 45

Scheme 45: REMOVAL
Scheme 45: REMOVAL

Scheme 46

Scheme 46
Scheme 46

Scheme 47

Scheme 47
Scheme 47

Scheme 48

Scheme 48
Scheme 48
  1. Disconnect the negative battery cable.
  2. Disconnect the radiator fan harness connector (1).
  3. Remove the coolant return hose (1) from the mounting bracket (2).
  4. Using a suitable tool, grasp the radiator fan hold down clamps (2) and pull up to remove the clamps from the mounting holes.
  5. Carefully pry the upper radiator hose and return hoses away from the cooling fan.
  6. Gently lift the radiator fan up and out of the vehicle.

Note. Lightly lubricate the two locating studs on the bottom of the radiator fan prior to installation.

Scheme 49

Scheme 49
Scheme 49
  1. Gently lower the radiator fan into the vehicle.
  2. Carefully pry the upper radiator hose and return hoses away from the cooling fan.
  3. Install the radiator fan locating studs (1) into the lower rubber mounts.
  4. Install the radiator fan hold down clamps (1).
  5. Route the coolant return hose (1) through the bracket (2) on the radiator fan.
  6. Connect the radiator fan harness connector (1).
  7. Connect the negative battery cable.

Scheme 50

Scheme 50: REMOVAL
Scheme 50: REMOVAL
  1. Disconnect the negative battery cable.
  2. Disconnect the radiator fan control module harness connector (2).
  3. Remove the retaining nuts at the top and bottom of the cooling fan module (1).
  4. Remove the cooling fan module from the engine compartment.

Scheme 51

Scheme 51: REMOVAL - SRT
Scheme 51: REMOVAL - SRT
  1. Disconnect the negative battery cable.
  2. Disconnect the radiator fan control module harness connector located next to the air pump in the left front of the vehicle.
  3. Remove the retaining nuts at the top and bottom of the cooling fan module (1).
  4. Remove the cooling fan module from the engine compartment.
  1. Position the radiator fan control module on the inner fender well studs.
  2. Install the upper and lower retaining nuts. Tighten the nuts to 10 N.m (89 in. lbs.).
  3. Connect the radiator fan control module harness connector.
  4. Connect the negative battery cable.
  1. Position the radiator fan control module (1) on the inner fender well studs next to the air pump (2).
  2. Install the upper and lower retaining nuts. Tighten the nuts to 10 N.m (89 in. lbs.).
  3. Connect the radiator fan control module (1) harness connector.
  4. Connect the negative battery cable.
  1. Clean any debris or corrosion from the engine coolant temperature sensor mounting surface.
  2. Use a small amount of petroleum jelly to lubricate the sensor seal.
  3. Install the engine coolant temperature sensor and retaining clip (1).
  4. Connect the engine coolant temperature sensor harness connector (1).
  5. Install the engine cover (1). Align the engine cover retaining clips to the rubber mounts, and push down firmly to connect engine cover to rubber mounts. NOTE: To ease the installation of the engine cover, apply a small amount of lubricant to the engine cover rubber mounts.
  6. Refill the cooling system. «(Refer to COOLING/ENGINE/COOLANT - STANDARD PROCEDURE)»(ref-250623-S38251009092007031500000) .
  7. Connect the negative battery cable.
  1. Clean any debris or corrosion from the engine coolant temperature sensor mounting surface.
  2. Use a small amount of petroleum jelly to lubricate the sensor seal.
  3. Install the engine coolant temperature sensor and retaining clip (1).
  4. Connect the engine coolant temperature sensor harness connector (1).
  5. Install the accessory drive belt idler pulley. Tighten the accessory drive belt idler pulley bolt (2) to 20 N.m (15 ft. lbs.).
  6. Install the supercharger idler pulley upper mounting bolt (1) and the lower mounting bolt (2). Tighten the mounting bolts to 20 N.m (15 ft. lbs.).
  7. Install the accessory drive belt to the accessory drive belt pulley. «(Refer to COOLING/ACCESSORY DRIVE - OPERATION)»(ref-250623-S01448650432007031500000) .
  8. Install the air pump tube assembly (1) and install the retaining bolts (2). «(Refer to EMISSIONS CONTROL/AIR INJECTION/AIR PUMP INLET TUBE - INSTALLATION)»(ref-250614-S15327098942007031500000) .
  9. Install the engine cover (1). Align the engine cover retaining clips to the engine rubber mounts, and push down firmly to connect engine cover to the rubber mounts. NOTE: To ease the installation of the engine cover, apply a small amount of lubricant to the engine cover rubber mounts.
  10. Refill the cooling system. «(Refer to COOLING/ENGINE/COOLANT - STANDARD PROCEDURE)»(ref-250623-S38251009092007031500000) .
  11. Connect the negative battery cable.
  1. Carefully lower the radiator into the vehicle.
  2. Connect the lower radiator hose (2).
  3. Connect the coolant recovery reservoir hose (1).
  4. Install the transmission cooler line (3) (automatic transmission only). Tighten the line to 10 N.m (89 in. lbs.).
  5. Connect the upper radiator hose (1).
  6. Connect the transmission cooler line (1) located in the middle front of the vehicle (automatic transmission only). «(Refer to COOLING/TRANSMISSION/TRANS COOLER LINES - INSTALLATION)»(ref-250623-S12387541792007031500000) .
  7. Using a suitable tool (1) install the radiator retaining clamps (2).
  8. Install the two condenser retainer bolts (1) into the radiator support. Tighten the bolts to 10 N.m (89 in. lbs.).
  9. Install the radiator fan. «(Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION)»(ref-250623-S38275167602007031500000) .
  10. Install the air inlet tubes.
  11. Refill the cooling system. «(Refer to COOLING/ENGINE/COOLANT - STANDARD PROCEDURE)»(ref-250623-S38251009092007031500000) .
  12. Connect the negative battery cable.
  13. Start the engine and check for coolant leaks.
  14. Recheck the coolant level.

Scheme 52

Scheme 52: DESCRIPTION
Scheme 52: DESCRIPTION

The pressure cap is located on the coolant reservoir. The pressure cap is made of high strength plastic, and screws onto the coolant reservoir tank. The cap contains a springloaded pressure relief valve, and a spring loaded vacuum relief valve.

  1. Clean all gasket surfaces.
  2. Position the water pump with a new gasket on the timing chain cover.
  3. Install the water pump bolts in the correct positions. Tighten the bolts to 35 N.m (26 ft. lbs.).
  4. Install the oil cooler hose (3) to the water pump.
  5. Install the hose clamp.
  6. Install the water pump pulley (2) and bolts. Tighten the water pump pulley bolts to 10 N.m (89 in. lbs.).
  7. Install the idler pulley (1) and bolt. Tighten the idler pulley bolt to 10 N.m (89 in. lbs.).
  8. Connect the lower radiator hose (2) and coolant by-pass hose (1).
  9. Install the generator. «(Refer to ELECTRICAL/CHARGING/GENERATOR - INSTALLATION)»(ref-250642-S42543175232007031500000) .
  10. Rotate the belt tensioner counterclockwise and install the accessory drive belt.
  11. Release the belt tensioner and remove the wrench.
  12. Install the air pump tube assembly (1) to the engine. «(Refer to EMISSIONS CONTROL/AIR INJECTION/AIR PUMP INLET TUBE - INSTALLATION)»(ref-250614-S15327098942007031500000) .
  13. Install the radiator fan. «(Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION)»(ref-250623-S38275167602007031500000) .
  14. Install the engine cover (1). Align the engine cover retaining clips to the rubber mounts, and push down firmly to connect engine cover to rubber mounts. NOTE: To ease the installation of the engine cover, apply a small amount of lubricant to the engine cover rubber mounts.
  15. Connect the negative battery cable.
  16. Fill the cooling system. «(Refer to COOLING/ENGINE/COOLANT - STANDARD PROCEDURE)»(ref-250623-S38251009092007031500000) .
  17. Start the engine and check for coolant leaks.
  18. Recheck the coolant level.
  1. Install the MAP sensor to the charge air cooler.
  2. Install a new charge air cooler flange gasket (1).
  3. Install the charge air cooler (3) to the supercharger. Tighten the charge air cooler mounting bolts (2) to 25 N.m (18 ft. lbs.).
  4. Install the charge air cooler rear mounting bolts. Tighten the charge air cooler rear mounting bolts (4) to 20 N.m (15 ft. lbs.).
  5. Install the supercharger on the engine. «(Refer to ENGINE/MANIFOLDS/SUPERCHARGER - INSTALLATION)»(ref-250616-S16990467162007031500000) .

Scheme 53

Scheme 53: DESCRIPTION
Scheme 53: DESCRIPTION

The charge air cooler circulation pump is mounted to the side of the charge air cooler radiator. The pump is used to circulate coolant between the charge air cooler radiator and the charge air cooler. The pump is a positive displacement pump, that operates on a pulsed 12 volt signal.

  1. Install the charge air cooler circulation pump to the mounting bracket.
  2. Install the charge air cooler circulation pump mounting bolt (1). Tighten the mounting bolt to 20 N.m (15 ft. lbs.).
  3. Reconnect the charge air cooler circulation pump harness connector (2).
  4. Reconnect the charge air cooler circulation pump inlet hose (2).
  5. Reconnect the charge air cooler circulation pump outlet hose (1).
  6. Refill the cooling system. «(Refer to COOLING/ENGINE/COOLANT - STANDARD PROCEDURE)»(ref-250623-S38251009092007031500000) .
  7. Start the engine and check for coolant leaks.
  8. Install the right side inner fender lining.
  9. Recheck the coolant level.

REMOVAL

  1. Remove the engine cover (1). Grasp both corners of the engine cover, and pull up firmly.
  2. Remove the accessory drive belt. «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)»(ref-250623-S19655078942007031500000) .
  3. Remove the pulley from the accessory drive belt tensioner.
  4. Remove the belt tensioner retaining bolts (1) and the belt tensioner (2).

REMOVAL - SRT

  1. Remove the engine cover (1). Grasp both corners of the engine cover, and pull up firmly.
  2. Remove the air pump tube assembly retaining bolts (2).
  3. Disconnect the air pump tube assembly (1) from the switchover valves.
  4. Remove the air pump tube assembly (1) from the engine.
  5. Release the tension on the accessory drive belt by attaching a wrench and pulling up on the tensioner and relocating the accessory drive belt.
  6. Remove the accessory drive belt tensioner pulley by holding the stud with a wrench and removing the nut.
  7. Remove the accessory drive belt tensioner bolts (1).
  8. Remove the accessory drive belt tensioner from the engine.

Scheme 54

Scheme 54
Scheme 54
  1. Position the belt tensioner (2) on the timing chain cover.
  2. Install the belt tensioner bolts (1). Tighten the bolts to 20 N.m (15 ft. lbs.).
  3. Install the wrench on the tensioner and remove the tensioner locking pin (1).
  4. Install the accessory drive belt. «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION)»(ref-250623-S38882998342007031500000) .
  5. Install the engine cover (1). Align the engine cover retaining clips to the rubber mounts, and push down firmly to connect engine cover to rubber mounts. NOTE: To ease the installation of the engine cover, apply a small amount of lubricant to the engine cover rubber mounts.
  6. Start the engine and verify the accessory drive belt is properly routed and seated.
  1. Install the accessory drive belt tensioner with the mounting bolts (1). Tighten the mounting bolts to 20 N.m (15 ft. lbs.).
  2. Install the accessory drive belt tensioner pulley to the stud. Tighten the pulley nut to 20 N.m (15 ft. lbs.).
  3. Release the tension on the tensioner and install the accessory drive belt.
  4. Install the air pump tube assembly (1) to the engine. «(Refer to EMISSIONS CONTROL/AIR INJECTION/AIR PUMP INLET TUBE - INSTALLATION)»(ref-250614-S15327098942007031500000) .
  5. Install the engine cover (1). Align the engine cover retaining clips to the rubber mounts, and push down firmly to connect engine cover to rubber mounts. NOTE: To ease the installation of the engine cover, apply a small amount of lubricant to the engine cover rubber mounts.
  6. Start the engine and verify the accessory drive belt is properly routed and seated.
  1. Remove the engine cover (1). Grasp both corners of the engine cover, and pull up firmly.
  2. Rotate the belt tensioner counterclockwise and release the tension on the accessory drive belt.
  3. Remove the accessory drive belt from the pulleys.
  4. Carefully release the wrench tension on the belt tensioner.
  5. Inspect the accessory drive belt. Refer to damage patterns. «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSPECTION)»(ref-250623-S16132945622007031500000) .
  6. Inspect the pulleys for wear or damage.
  7. Replace the accessory drive belt or pulleys as necessary.
  1. Remove the engine cover (1). Grasp both corners of the engine cover and pull up firmly.
  2. Remove the air pump tube retaining bolts (2).
  3. Remove the air pump tube assembly from the engine (1). «(Refer to EMISSIONS CONTROL/AIR INJECTION/AIR PUMP INLET TUBE - REMOVAL)»(ref-250614-S38752648592007031500000) .
  4. Rotate the belt tensioner counterclockwise and release the tension on the accessory drive belt.
  5. Remove the accessory drive belt from the pulleys.
  6. Carefully release the wrench tension on the belt tensioner.
  7. Remove the supercharger idler pulley upper retaining bolt (1) and lower retaining bolt (2).
  8. Remove the supercharger idler pulley.
  9. Remove the accessory drive belt from the engine.
  10. Inspect the accessory drive belt. Refer to damage patterns. «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSPECTION)»(ref-250623-S16132945622007031500000) .
  11. Inspect the pulleys for wear or damage.
  12. Replace the accessory drive belt or pulleys as necessary.
  1. Route the accessory drive belt onto the engine pulleys.
  2. Rotate the belt tensioner counterclockwise and install the accessory drive belt over the tensioner pulley.
  3. Release the belt tensioner and remove the wrench.
  4. Install the engine cover (1). Align the engine cover retaining clips to the rubber mounts, and push down firmly to connect engine cover to rubber mounts. NOTE: To ease the installation of the engine cover, apply a small amount of lubricant to the engine cover rubber mounts.
  5. Start the engine and verify the accessory drive belt is properly routed and seated.
  1. Route the accessory drive belt onto the engine pulleys.
  2. Install the supercharger idler pulley upper mounting bolt (1) and the lower mounting bolt (2). Tighten the bolts to 20 N.m (15 ft. lbs.).
  3. Rotate the belt tensioner counterclockwise and install the accessory drive belt over the tensioner pulley.
  4. Release the belt tensioner and remove the wrench.
  5. Install the air pump tube assembly (1) to the engine. «(Refer to EMISSIONS CONTROL/AIR INJECTION/AIR PUMP INLET TUBE - INSTALLATION)»(ref-250614-S15327098942007031500000) .
  6. Install the engine cover (1). Align engine cover retaining clips to the rubber mounts, and push down firmly to connect engine cover to rubber mounts. NOTE: To ease the installation of the engine cover, apply a small amount of lubricant to the engine cover rubber mounts.
  7. Start the engine and verify the accessory drive belt is properly routed and seated.

Note. A small dowel rod can be inserted into the accessory drive belt tensioner to hold the tensioner in place while performing repairs.

Scheme 55

Scheme 55
Scheme 55

Scheme 56

Scheme 56
Scheme 56
  1. Rotate the belt tensioner counterclockwise and release the tension on the accessory drive belt.
  2. Relocate the accessory drive belt away from the idler pulley (4).
  3. Remove the idler pulley bolt cover (1).
  4. Remove the bolt (1) and the idler pulley (2) from the engine.
  5. Check the pulley bearing for any wear, looseness or noise. Replace if necessary.

REMOVAL - IDLER PULLEY (SRT)

Note. A small dowel rod can be inserted into the accessory drive belt tensioner to hold the tensioner in place while performing repairs.

Scheme 57

Scheme 57
Scheme 57
  1. Rotate the belt tensioner counterclockwise and release the tension on the accessory drive belt.
  2. Slide the accessory drive belt away from the idler pulley (8).
  3. Remove the bolt (1) and the idler pulley from the engine.
  4. Check the pulley bearing for looseness and noise. Replace if necessary.

REMOVAL - SUPERCHARGER IDLER (SRT)

  1. Remove the engine cover (1). Grasp both corners of the engine cover and pull up firmly.
  2. Remove the air tube assembly (1) by removing the retaining bolts (2).
  3. Release the tension on the accessory drive belt.
  4. Remove the supercharger idler pulley retainer bolts (1) and (2) and the pulley assembly.
  1. Position the idler pulley (2) on the engine.
  2. Install the idler pulley bolt (1). Tighten to 20 N.m (15 ft. lbs.).
  3. Install the bolt cover (1) on the idler pulley. NOTE: If a dowel rod was inserted into the accessory drive belt tensioner, remove rod.
  4. Rotate the belt tensioner counterclockwise and install the accessory drive belt over the idler pulley.
  5. Carefully release the belt tensioner and remove the wrench.
  6. Install and properly route the accessory drive belt. «(Refer to COOLING/ACCESSORY DRIVE - OPERATION)»(ref-250623-S01448650432007031500000) .

INSTALLATION - IDLER PULLEY (SRT)

  1. Position the idler pulley on the engine.
  2. Install the idler pulley bolt (1). Tighten the idler pulley bolt to 20 N.m (15 ft. lbs.).
  3. Rotate the belt tensioner counterclockwise and install the accessory drive belt over the idler pulley. NOTE: If a dowel rod was inserted into the accessory drive belt tensioner, remove rod.
  4. Carefully release the belt tensioner and remove the wrench.
  5. Install and properly route the accessory drive belt. «(Refer to COOLING/ACCESSORY DRIVE - OPERATION)»(ref-250623-S01448650432007031500000) .

INSTALLATION - SUPERCHARGER IDLER (SRT)

  1. Install the supercharger idler pulley retainer bolts (1) and (2), and the pulley assembly. Tighten bolts to 20 N.m (15 ft. lbs.).
  2. Install the accessory drive belt.
  3. Install the air tube assembly (1) by installing the retaining bolts (2).
  4. Install the engine cover (1). Align engine cover retaining clips to the rubber mounts, and push down firmly to connect engine cover to rubber mounts. NOTE: To ease the installation of the engine cover, apply a small amount of lubricant to the engine cover rubber mounts.

Scheme 58

Scheme 58: REMOVAL
Scheme 58: REMOVAL
1. TRANSMISSION LINE RETAINERS
2. BANJO BOLTS
3. FLEXIBLE LINES
4. STEEL LINES
5. COPPER LINES

Note. To service the front copper transmission cooler lines (5) the radiator must be removed. (Refer to COOLING/ENGINE/RADIATOR - REMOVAL) .

  1. Raise and support the vehicle.
  2. Remove the lower splash shield.
  3. Disconnect the fittings at either end of the line being serviced.
  4. Remove the line retainers (1) and the cooler line(s) as necessary.
  1. Position the cooler line(s) and loosely connect the fittings.
  2. Install the retainers and bolts for the cooler line(s). NOTE: Replace the copper washers if the banjo bolts are removed.
  3. Tighten the cooler line fittings or banjo bolts to 20 N.m (15 ft. lbs.).
  4. Tighten the transmission cooler line retaining bolts to 10 N.m (89 in. lbs.).
  5. Lower the vehicle.
  6. Install the radiator if removed. «(Refer to COOLING/ENGINE/RADIATOR - INSTALLATION)»(ref-250623-S15046803162007031500000) .
  7. Check the transmission fluid level. «(Refer to TRANSMISSION/TRANSAXLE/AUTOMATIC - NAG1/FLUID - STANDARD PROCEDURE)»(ref-250624-S15983379352007031500000) .

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