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Installation - Right Side: Removal & Installation Chrysler Crossfire I

Mechanical 9 illustrations ~1357 words

REMOVAL

  1. Remove the generator «(Refer to ELECTRICAL/CHARGING/GENERATOR - REMOVAL)»(ref-250642-S27922636232007031500000) .
  2. Remove the timing chain tensioner (1).
  1. Install the timing chain tensioner. Tighten tensioner to 80 N.m (59 ft. lbs.).
  2. Install the generator «(Refer to ELECTRICAL/CHARGING/GENERATOR - INSTALLATION)»(ref-250642-S42543175232007031500000) .

Scheme 109

Scheme 109
Scheme 109
  1. Disconnect the negative battery cable.
  2. Drain the cooling system «(Refer to COOLING/ENGINE/COOLANT - STANDARD PROCEDURE)»(ref-250623-S38251009092007031500000) .
  3. Remove the engine cover «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(ref-250615-S26276682392007031500000) .
  4. Remove the radiator fan «(Refer to COOLING/ENGINE/RADIATOR FAN - REMOVAL)»(ref-250623-S19590179442007031500000) .
  5. Remove the accessory drive belt «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)»(ref-250623-S19655078942007031500000) .
  6. Remove the idler pulley.
  7. Remove accessory drive belt tensioner «(Refer to COOLING/ACCESSORY DRIVE/BELT TENSIONERS - REMOVAL)»(ref-250623-S11396632562007031500000) .
  8. Remove the vibration damper «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL)»(ref-250615-S18631891782007031500000) .
  9. Disconnect lower radiator and heater hoses from the water pump.
  10. Remove the power steering pump «(Refer to STEERING/PUMP - REMOVAL)»(ref-250617-S28732702552007031500000) .
  11. Remove the AIR pump.
  12. Remove the cylinder head covers «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL)»(ref-250615-S03807371432007031500000) .
  13. Remove the front cylinder head to timing chain cover retaining bolts.
  14. Remove the generator «(Refer to ELECTRICAL/CHARGING/GENERATOR - REMOVAL)»(ref-250642-S27922636232007031500000) .
  15. Raise and support vehicle.
  16. Remove the lower oil pan «(Refer to ENGINE/LUBRICATION/OIL PAN - REMOVAL)»(ref-250615-S13234564252007031500000) .
  17. Remove the upper oil pan «(Refer to ENGINE/LUBRICATION/OIL PAN - REMOVAL)»(ref-250615-S13234564252007031500000) .
  18. Remove the starter «(Refer to ELECTRICAL/STARTING/STARTER MOTOR - REMOVAL)»(ref-250629-S40399068962007031500000) .
  19. Rotate the crankshaft to 40° ATDC.
  20. Using Special Tool 9102 (1) Flywheel Locking Tool, lock the flywheel by inserting the tool into the starter opening.
  21. Remove the timing chain tensioner «(Refer to ENGINE/VALVE TIMING/TMNG BELT/CHAIN TENSIONER&PULLEY - REMOVAL)»(ref-250615-S15789800702007031500000) .
  22. Remove the timing chain cover bolts and cover.

Scheme 110

Scheme 110
Scheme 110

Scheme 111

Scheme 111
Scheme 111
  1. Be sure valve timing is still locked at 40° ATDC «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION)»(ref-250615-S09581061972007031500000) . NOTE: Apply sealer ONLY to the area marked (1) as shown. If porous points are visible at the cylinder heads or at the rear of the engine near the sealing surface of the cylinder head gasket, apply sealant at these points. The sealant must be applied only as a 2.0 mm +/- 0.5 mm bead, assembled within 10 minutes, and not be flattened or spread.
  2. Apply a 1.5 to 2.0 mm bead of Loctite 5900 or equivalent sealer to the area marked (1) as shown.
  3. Position the timing chain cover on the front of the engine. NOTE: Ensure that the bolts indicated by the arrows are installed with thread sealer prior to assembly.
  4. Install the timing chain cover bolts and tighten to 20 N.m (15 ft. lbs.).
  5. Install the timing chain tensioner (1). Tighten to 80 N.m (59 ft. lbs.) «(Refer to ENGINE/VALVE TIMING/TMNG BELT/CHAIN TENSIONER&PULLEY - INSTALLATION)»(ref-250615-S14537904902007031500000) .
  6. Remove Special Tool 9102 Flywheel Locking Tool (1) from the engine.
  7. Install the starter «(Refer to ELECTRICAL/STARTING/STARTER MOTOR - INSTALLATION)»(ref-250629-S39333530842007031500000) .
  8. Install the upper oil pan «(Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION)»(ref-250615-S09424839942007031500000) .
  9. Install the lower oil pan «(Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION)»(ref-250615-S09424839942007031500000) .
  10. Install the generator. «(Refer to ELECTRICAL/CHARGING/GENERATOR - INSTALLATION)»(ref-250642-S42543175232007031500000) . NOTE: Apply a thin coat of lubricant to head bolt threads before installing.
  11. Install the front cylinder head to timing chain cover bolts. Tighten bolts to 20 N.m (7-15 ft. lbs.).
  12. Install the cylinder head covers «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION)»(ref-250615-S17944976732007031500000) .
  13. Install the AIR pump.
  14. Install the power steering pump, return hose (1), and pressure hose (2) «(Refer to STEERING/PUMP - INSTALLATION)»(ref-250617-S21599301252007031500000) .
  15. Install the lower radiator and heater hoses to the water pump.
  16. Install the vibration damper «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION)»(ref-250615-S31916650382007031500000) .
  17. Install the idler pulley. «(Refer to COOLING/ACCESSORY DRIVE/IDLER PULLEY - INSTALLATION)»(ref-250623-S18495792282007031500000) .
  18. Install the accessory drive belt tensioner «(Refer to COOLING/ACCESSORY DRIVE/BELT TENSIONERS - INSTALLATION)»(ref-250623-S40180305042007031500000) .
  19. Install the accessory drive belt «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION)»(ref-250623-S38882998342007031500000) .
  20. Install the radiator fan «(Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION)»(ref-250623-S38275167602007031500000) .
  21. Install the engine cover «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION)»(ref-250615-S14278514492007031500000) .
  22. Refill all engine fluids to specifications.
  23. Connect the negative battery cable.

Scheme 112

Scheme 112: REMOVAL
Scheme 112: REMOVAL

Scheme 113

Scheme 113
Scheme 113
  1. Remove the timing chain cover. «(Refer to ENGINE/VALVE TIMING/GEAR HOUSING COVER - REMOVAL)»(ref-250615-S21230849232007031500000) .
  2. Remove the oil pump drive chain (2) and tensioner (1). «(Refer to ENGINE/LUBRICATION/OIL PUMP - REMOVAL)»(ref-250615-S30994579282007031500000) .
  3. Remove the left and right camshaft sprocket bolts (1).
  4. Remove the timing chain and camshaft sprockets.
  5. Remove the timing chain crankshaft sprocket (2).
  6. Clean and inspect all gasket surfaces, chain guides, and sprockets for wear or damage. Repair or replace as necessary.

Scheme 114

Scheme 114
Scheme 114
  1. Invert the engine on the engine stand.
  2. Install the crankshaft sprocket (2).
  3. Ensure the crankshaft has maintained 40 degrees ATDC. If not, rotate until aligned with 40 degree marking.
  4. Align the balance shaft sprocket with the timing mark (3) and the copper teeth (1) of the timing chain.
  5. Insert the camshaft sprockets (6) into the timing chain and align the camshaft sprocket timing marks (4) and (5) with the copper teeth (1) of the timing chain.
  6. Install the timing chain with the sprockets and route within in the timing chain guides (1).
  7. Using Special Tools 9104 (1) and 9105 Camshaft Locating Plates, lock the camshaft sprockets.
  8. Install the oil pump, the oil pump drive chain (2) and the oil pump drive chain tensioner (1). «(Refer to ENGINE/LUBRICATION/OIL PUMP - INSTALLATION)»(ref-250615-S02284147922007031500000) .
  9. Rotate the engine to the upright position.
  10. Install the timing chain cover. Tighten the bolts to 20 N.m (15 ft. lbs.). «(Refer to ENGINE/VALVE TIMING/GEAR HOUSING COVER - INSTALLATION)»(ref-250615-S36901108062007031500000) .
  11. Remove Special Tools 9104 and 9105 Camshaft Locating Plates from the camshaft sprockets.

Scheme 115

Scheme 115: DESCRIPTION
Scheme 115: DESCRIPTION

A balance shaft is used to compensate for the rocking motion inherent in a 90-degree V-6 engine. It rotates at engine speed in the opposite direction. Mounted above the crankshaft in the cylinder block, it is driven by the timing chain.

Scheme 116

Scheme 116
Scheme 116

Scheme 117

Scheme 117
Scheme 117
  1. Remove the timing chain cover. «(Refer to ENGINE/VALVE TIMING/GEAR HOUSING COVER - REMOVAL)»(ref-250615-S21230849232007031500000) .
  2. Rotate the crankshaft and align the basic valve timing to 40 degrees ATDC.
  3. Remove the starter. «(Refer to ELECTRICAL/STARTING/STARTER MOTOR - REMOVAL)»(ref-250629-S40399068962007031500000) .
  4. Using Special Tool 9102 Flywheel Locking Tool (1), lock the flywheel.
  5. Remove the timing chain. «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL)»(ref-250615-S41490916842007031500000) .
  6. Remove the rear crankshaft oil seal. «(Refer to ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR - REMOVAL)»(ref-250615-S37110079062007031500000) .
  7. Hold the balance shaft rear counter weight (1) with a drift, remove the rear retaining bolt (2).
  8. Remove the balance shaft rear counter weight (1) from the balance shaft. 1 - CAMSHAFT POSITION SENSOR 2 - BALANCE SHAFT FRONT COUNTER WEIGHT 3 - BALANCE SHAFT REAR COUNTER WEIGHT 4 - REAR RETAINING BOLT 5 - BALANCE SHAFT 6 - LOCKING PLATE BOLT
  9. Remove the balance shaft locking plate bolt (6) and locking plate at the front of the engine block.
  10. Remove the balance shaft (5) from the front of the engine.
1 - CAMSHAFT POSITION SENSOR
2 - BALANCE SHAFT FRONT COUNTER WEIGHT
3 - BALANCE SHAFT REAR COUNTER WEIGHT
4 - REAR RETAINING BOLT
5 - BALANCE SHAFT
6 - LOCKING PLATE BOLT
  1. Position the balance shaft (5) into the engine balance shaft bore from the front. NOTE: Balance shaft rear retaining bolt (4) must be replaced if length exceeds 50 mm.
  2. Install the balance shaft rear counter weight (3) onto the balance shaft (5) and install the rear retaining bolt (4). Tighten the bolt to 20 N.m (15 ft. lbs.). Rotate the bolt (4) an additional 90°.
  3. Install the balance shaft locking plate and locking plate bolt (6). Tighten the balance shaft locking plate bolt to 20 N.m (15 ft. lbs.).
  4. Install the crankshaft rear radial oil seal. «(Refer to ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR - REMOVAL)»(ref-250615-S37110079062007031500000) .
  5. Install the timing chain. «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION)»(ref-250615-S09581061972007031500000) .
  6. Install the timing chain cover. «(Refer to ENGINE/VALVE TIMING/GEAR HOUSING COVER - INSTALLATION)»(ref-250615-S36901108062007031500000) .
  7. Remove the Special Tool 9102 Flywheel Locking Tool (1) from the engine and install the starter. «(Refer to ELECTRICAL/STARTING/STARTER MOTOR - INSTALLATION)»(ref-250629-S39333530842007031500000) .
  1. Remove the timing chain (1). «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL)»(ref-250615-S41490916842007031500000) .
  2. Remove the timing chain guides (1) off of the mounting pins. Inspect and replace worn or damaged guides as required.
  1. Install the timing chain guides on the mounting pins. Lubricate surface with engine oil.
  2. Install the timing chain. «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION)»(ref-250615-S09581061972007031500000) .

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