Emissions Control System: Removal & Installation Chrysler Crossfire I

REMOVAL

For removal procedure, (Refer to EMISSIONS CONTROL/EVAPORATIVE EMISSIONS/VAPOR CANISTER - REMOVAL) .

INSTALLATION

For installation procedure, (Refer to EMISSIONS CONTROL/EVAPORATIVE EMISSIONS/VAPOR CANISTER - INSTALLATION) .

Scheme 24

The Positive Crankcase Ventilation (PCV) System consists of a draft-tube style throttle body insert (2) and hoses (1 and 3) connected between the cylinder head covers and the throttle body insert (2).

Scheme 25

Crankcase ventilation is accomplished by means of a draft-tube style insert (2) protruding through the throttle body into the intake airstream (4). The crankcase gases are drawn into the intake manifold when air passing the tube insert creates a vacuum in the Crankcase Vent Hoses (1 and 3).

INSTALLATION - 3.2L

1. Install solenoid (3) on bracket (5).
2. Connect vapor hoses (1 and 4) to solenoid (3).
3. Connect connector (2) to solenoid (3).

INSTALLATION - 3.2L SRT

1. Install solenoid (3) on bracket (5).
2. Connect vapor hoses (1 and 4) to solenoid (3).
3. Connect connector (2) to solenoid (3).

1. Install the charcoal canister shutoff valve (1) to EVAP canister (2) using new O-ring (3).
2. Connect the charcoal canister shutoff valve harness connector (1).
3. Connect the hoses (2).
4. Slide the EVAP canister to the right, on to mounting bracket.
5. Install the splash shield and retaining nuts.
6. Lower the vehicle.
7. Connect the negative battery cable.

1. Position the solenoid to valve and loosely install solenoid to valve bolt (2).
2. Install the valve bolt (1) to cylinder head. Tighten to 31 N.m (23 ft. lbs.).
3. Tighten the solenoid to valve bolt (2) to 11 N.m (95 in. lbs.).
4. Connect the vacuum hoses (2).
5. Connect the EGR solenoid harness connector (1).
6. Install the air cleaner housing.
7. Connect the negative battery cable.

Scheme 26

1. Remove the air cleaner housing.
2. Remove the EGR tube mounting bolts (1) at the intake manifold.
3. Remove the EGR tube flange nut (2) at the EGR valve.
4. Remove the EGR tube.
5. Clean the gasket surfaces on the EGR tube and intake manifold. Discard old gasket.

Note. Any loose dirt can lodge between the tube and manifold and cause vacuum leakage that will give a rough idle and reduced manifold vacuum.

1. Loosely install the EGR tube flange nut (2) to the EGR valve.
2. Position the new gasket between tube and intake manifold.
3. Install the tube bolts (1) to intake manifold. Tighten to 31 N.m (23 ft. lbs.).
4. Tighten the EGR tube flange nut (2) to 11 N.m (95 in. lbs.).
5. Install the air cleaner housing.

Scheme 27

The EGR Valve consists of three major components

1. EGR Valve
2. EGR Solenoid
3. EGR Tube

The EGR Valve (3) is located at the right rear of the engine and is attached to the right cylinder head, to the right of the Throttle Body (4). The EGR Solenoid (2) is attached to the EGR Valve (3) on the throttle body side of the valve. The EGR Tube (1) connects the EGR Valve (3) to the rear of the Intake Manifold (5).

1. Install air pump to the air pump mounting bracket.
2. Install the air pump retaining nuts (1). Tighten nuts to 7 N.m (62 in. lbs.).
3. Connect the air pump harness connector (2).
4. Connect the air pump tube assembly (1) to the air pump.
5. Connect the negative battery cable.

Scheme 28

Scheme 29

1. Disconnect the negative battery cable.
2. Remove the air cleaner housing.
3. Disconnect the air pump switchover solenoid harness connector (2).
4. Disconnect the vacuum lines (1).
5. Pull the air pump switchover solenoid locking tab (1) away from air pump switchover solenoid (2).
6. Remove the air pump switchover solenoid (2) from air pump switchover solenoid retaining bracket (3).

1. Position the air pump switchover solenoid (2) above air pump switchover solenoid mounting bracket (3) and lower until air pump switchover solenoid locking tab (1) snaps into place.
2. Connect the vacuum lines (1).
3. Connect the air pump switchover solenoid harness connector (2).
4. Install the air cleaner housing.
5. Connect the negative battery cable.

Scheme 30

1. Disconnect the negative battery cable.
2. Remove the air cleaner housing.
3. Disconnect the vacuum line (3).
4. Disconnect the air pump switchover tube (2).
5. Remove the air pump switchover valve retaining bolt (4).
6. Remove the air pump switchover valve (1) discard the old gasket.

1. Position the new gasket between intake manifold and air pump switchover valve (1).
2. Install the retaining bolt (4). Tighten bolt to 20 N.m (177 in. lbs.).
3. Connect the vacuum line (3).
4. Connect the air pump switchover tube (2).
5. Install the air cleaner housing.
6. Connect the negative battery cable.

Scheme 31

Scheme 32

1. Remove the engine cover. Grasp both of the corners of the front engine cover and pull up firmly.
2. Remove the air pump tube assembly retaining bolts (2).
3. Disconnect the air pump tubes (1) from the air pump and solenoids.
4. Remove the air pump tube assembly from the engine.

INSTALLATION - SRT

1. Install the air pump tube assembly (1) to the engine.
2. Connect the air pump tubes (1) to the air pump and the switchover valves.
3. Install the air pump tube assembly retaining bolts (2). Tighten the bolts to 10 N.m (89 in. lbs.).
4. Install the engine cover. Realign the engine cover retaining clips to the mounting brackets and push down firmly to connect the engine cover to the mounting brackets.