Engine Cooling System & Automatic Transmission Cooling System Chrysler Crossfire I final

Scheme 1

A conventional cross-flow aluminum core radiator (4) is used to cool the engine. The Coolant Recovery Reservoir (1) is equipped with a Coolant Level Sensor. The Coolant Level Sensor in the Coolant Recovery Reservoir notifies the driver if there is insufficient coolant in the system by illuminating the low engine coolant warning lamp in the Instrument Cluster. An Electric Cooling Fan (2) is activated by the Radiator Fan Control Module. The cooling system is also equipped with an additional electric Coolant Circulation Pump. The pump is used to keep the passenger cabin warm by circulating coolant through the heater core when the engine is off.

OPERATION

Scheme 2

1. When engine (2) is cold: Thermostat (6) is closed, cooling system has no flow through the radiator (7). The coolant flows through the engine, heater core (3), coolant recovery reservoir (1), and an internal engine by-pass.
2. When engine (2) is warm: Thermostat (6) is open, coolant flows through the radiator (7), heater core (3), coolant recovery reservoir (1), and by-pass.

The cooling systems primary purpose is to maintain engine temperature in a range that will provide satisfactory engine performance and emission levels under all expected driving conditions. It also provides hot coolant for heater, and cooling for automatic transmission fluid. It does this by transferring heat from engine metal to coolant, moving this heated coolant to the radiator, and then transferring this heat to the ambient air. The cooling system is also equipped with an additional electric coolant circulation pump. The pump is used to keep the passenger cabin warm by circulating coolant through the heater core when the engine is off.

PRELIMINARY CHECKS

Determine what driving conditions caused the complaint. One or more of the following conditions may be the cause of the complaint

1. Prolonged Idle
2. Very High Ambient Temperature
3. Slow Traffic
4. Traffic Jams
5. High Speed
6. Steep Grades

1. RECENT SERVICE OR ACCIDENT REPAIR: Determine if any recent service has been performed on the vehicle that may affect the cooling system operation. One or more of the following conditions may be the cause of the complaint: Engine adjustments (incorrect timing) Slipping engine accessory drive belt(s) Brakes (possibly dragging) Changed parts. Incorrect water pump, or pump rotating in wrong direction due to belt not correctly routed. Reconditioned radiator or cooling system refilling (possibly under filled or air trapped in system).

LEAK TESTING

With the engine not running, wipe the coolant recovery reservoir neck sealing area clean.

Scheme 3

Attach a radiator pressure tester (1) to the coolant recovery reservoir with Special Tool 9107 Pressure Tester Adapter (2). Apply 104 kPa (15 psi) pressure to the cooling system. If the pressure drops more than 2 psi in 2 minutes inspect all points for external leaks.

All hoses, radiator and heater, should be moved while at 15 psi since some leaks occur while driving due to engine rock, vibration, etc.

If there are no external leaks after the gauge dial shows a drop in pressure, detach the tester. Start engine and run the engine to normal operating temperature in order to open the thermostat and allow the coolant to expand. Reattach the tester. If the needle on the dial fluctuates it indicates a combustion leak, usually a head gasket leak.

If the needle on the dial does not fluctuate, race the engine a few times. If an abnormal amount of coolant or steam is emitted from the tail pipe, it may indicate a faulty head gasket, cracked engine block, or cylinder head.

There may be internal leaks which can be determined by removing the oil dipstick. If water globules appear intermixed with the oil it will indicate an internal leak in the engine. If there is an internal leak, the engine must be disassembled for repair.

Scheme 4

1. DO NOT remove the pressure cap first. With the engine cold, raise and support the vehicle on a hoist and locate the radiator draincock. NOTE: Radiator draincock is located on the left/lower side of radiator facing to rear of vehicle.
2. Attach one end of a hose to the draincock (2). Put the other end into a clean container. Open draincock and drain the coolant from the radiator. This will also empty the coolant recovery reservoir (1). When the tank is empty, remove the pressure cap and continue draining the cooling system.

REFILLING

1. Tighten the radiator draincock and the cylinder block drain plug(s) (if removed). CAUTION: Failure to purge air from the cooling system can result in an overheating condition and severe engine damage.
2. Fill system using a 50/50 mixture of antifreeze/coolant and distilled water. Fill the coolant recovery reservoir to service line and install pressure cap. NOTE: The engine cooling system will push any remaining air into the coolant recovery reservoir within about an hour of normal driving. As a result, a drop in coolant level in the coolant recovery reservoir may occur. If the engine cooling system overheats and pushes coolant into the overflow side of the coolant recovery reservoir, this coolant will be drawn back into the cooling system ONLY IF THE PRESSURE CAP IS LEFT ON RESERVOIR. Removing the pressure cap breaks the vacuum path between the two reservoir sections and the coolant will not return to cooling system.
3. With the heater control unit in the HEAT position, operate the engine with the coolant recovery reservoir cap in place.
4. Add coolant to the coolant recovery reservoir as necessary. Only add coolant to the coolant recovery reservoir when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion.

Note. The coolant recovery reservoir has two chambers. Coolant will normally only be in the outboard (larger) of the two. The inboard chamber is only to recover coolant in the event of an overheat or after a recent service fill. The inboard chamber should normally be empty. If there is coolant in the overflow side of the coolant recovery reservoir (after several warm/cold cycles of the engine) and the coolant level is above the cold full line when cold, disconnect the end of the overflow hose at the radiator and lower it into a clean container. Allow the coolant to drain into the container until emptied. Reconnect the overflow hose to radiator.

CLEANING/REVERSE FLUSHING

Reverse flushing of the cooling system, is the forcing of water through the cooling system in the reverse direction of normal flow. This is done using compressed air and water. It is usually only necessary when the cooling system is extremely contaminated and evidence of partial plugging is evident.

CHEMICAL CLEANING

If visual inspection indicates the formation of sludge or scaly deposits, use a radiator cleaner (Mopar Radiator Kleen or equivalent) before flushing. This will soften scale and other deposits and aid the flushing operation.

REVERSE FLUSHING RADIATOR

Disconnect the radiator hoses from the radiator. Attach a section of radiator hose to the radiator bottom outlet fitting and insert the flushing gun. Connect a water supply hose and air supply hose to the flushing gun.

Allow the radiator to fill with water. When the radiator is filled, apply air in short blasts allowing the radiator to refill between blasts. Continue this reverse flushing until clean water flows out through the rear of the radiator cooling tube passages. For more information, refer to operating instructions supplied with the flushing equipment.

CLEANING

Drain the cooling system and refill with clean water. Refer to STANDARD PROCEDURE .

Run the engine with the radiator cap installed until the upper radiator hose is hot. Stop the engine, and drain the water from system. If the water is dirty, refill, run, and drain the system again, until the water runs clear. After flushing, refill the cooling system with a 50/50 mixture of the recommended antifreeze/coolant and distilled water.

INSPECTION

After performing a cleaning/flush procedure, carefully inspect all hoses, clamps and connections for deterioration and leaks. Inspect the radiator and heater core for leaks.

TORQUE

TORQUE SPECIFICATIONS

FILL VOLUMES

Scheme 5

Scheme 6

DESCRIPTION

ETHYLENE-GLYCOL MIXTURES

The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar® Antifreeze/Coolant, 5 Year/100,000 Mile Formula (ethylene-glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37°C (-35°F).

The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water.

Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22°C (-8°F ).

PROPYLENE-GLYCOL MIXTURES

It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32°C (-26°F). 5°C higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125°C (257°F ) at 96.5 kPa (14 psi), compared to 128°C (263°F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up on a cooling system designed for ethylene-glycol. Propylene- glycol also has poorer heat transfer characteristics than ethylene-glycol. This can increase cylinder head temperatures under certain conditions.

Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene-glycol.

Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the antifreeze/coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water.

CONCENTRATION TESTING

Coolant concentration should be checked when any additional coolant is added to the cooling system, or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -46°C (-50°F). The use of a hydrometer or a refractometer can be used to test coolant concentration.

A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of antifreeze/coolant, the larger the number of balls that will float, and higher the freeze protection.

A Refractometer, Special Tool 8286, will test the amount of antifreeze/coolant in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid.

Scheme 7

1. Partially drain the cooling system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
2. Disconnect the coolant level sensor harness connector (2).
3. Depress the locking tabs and pull the coolant level sensor (1) from the coolant recovery reservoir.

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. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
5. Start the engine and check for coolant leaks.
6. Recheck the coolant level and adjust as necessary.

A pellet-type thermostat controls the operating temperature of the engine by controlling the amount of coolant flow to the radiator. The thermostat is opened when the engine temperature reaches 195°F (90°C). When opened, the thermostat allows engine coolant to flow to the radiator. This provides quick engine warm up and overall temperature control.

Scheme 8

The same thermostat is used for winter and summer seasons. An engine should not be operated without a thermostat, except for servicing or testing. Operating the engine without a thermostat can cause the following problems

1. Longer engine warm-up time
2. Unreliable warm-up performance
3. Increased exhaust emissions
4. Crankcase condensation

This condensation can result in sludge formation.

The wax pellet is located in a sealed container at the spring end of the thermostat. When heated, the pellet expands, overcoming closing spring tension and water pump pressure to force the valve to open.

Scheme 9

1. Remove the thermostat from the engine. See «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
2. Suspend the thermostat in a container of water. CAUTION: Never use a welding torch or soldering torch as the sudden introduction of heat alters the structure of the metal!
3. Heat the container and thermostat. NOTE: The rate of increase should not be more than 1°C to 2°C/min from about 8 °C below the start of opening of the coolant thermostat.
4. Measure the temperature of the water.
5. Heat the water to the temperature specified on the thermostat. Allow the thermostat to fully open, and then measure the distance of the stroke.
6. If the specifications are not achieved, install a new coolant thermostat.

Scheme 10

1. Remove the air cleaner housing. Refer to «REMOVAL»(ref-306563-S23334034382008121700000) .
2. Partially drain the cooling system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
3. Disconnect the upper radiator hose. NOTE: The thermostat housing and the thermostat are serviced as an assembly. The thermostat cannot be serviced separately.
4. Remove the thermostat housing retaining bolts and remove the thermostat and housing from the engine.

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. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
4. Start the engine and check for coolant leaks.
5. Recheck the coolant level and adjust as necessary.

The pressure chamber keeps the coolant free of trapped air, provides a volume for expansion and contraction, and provides a convenient and safe method for checking and adjusting coolant level at atmospheric pressure. It also provides some reserve coolant to cover minor leaks, evaporation or boiling losses. The overflow chamber allows coolant recovery in case of an overheat.

Scheme 11

1. Disconnect the negative battery cable.
2. Partially drain the cooling system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
3. Disconnect the small coolant hose at the coolant recovery reservoir (4).
4. Disconnect the large coolant hose at the bottom of the coolant recovery reservoir (3).
5. Disconnect the coolant level sensor harness connector (2) at the coolant recovery reservoir.
6. Disconnect the coolant overflow hose (1).
7. Remove the two retaining nuts (2) and lift the coolant recovery reservoir from the engine compartment.

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. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
8. Connect the negative battery cable.
9. Start the engine and check for coolant leaks.
10. Recheck the coolant level.

Scheme 12

Scheme 13

Scheme 14

Scheme 15

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 16

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 17

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.

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.

The engine coolant temperature sensor provides an input to the powertrain control module (PCM). As coolant temperature varies, the engine coolant temperature sensor resistance changes, resulting in a variable input voltage to the PCM.

When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached.

The engine coolant sensor input also determines operation of the radiator fan.

Scheme 18

Scheme 19

Scheme 20

1. Disconnect the negative battery cable.
2. Partially drain the cooling system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
3. Remove the engine cover (1). Grasp both corners of the engine cover, and pull up firmly.
4. Disconnect the engine coolant temperature sensor harness connector (1).
5. Pull up on the engine coolant temperature sensor retaining clip (1) and slide the engine coolant temperature sensor out of the housing.
6. Remove the engine coolant temperature sensor from the engine.

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. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
7. Connect the negative battery cable.

The Crossfire has a cross flow type radiator (4). The main radiator core is made of aluminum, and the side tanks are made of plastic (3).

Note. Handle the radiator with care, plastic tanks while stronger than brass, are subject to damage.

Scheme 21

Scheme 22

Scheme 23

Scheme 24

1. Disconnect the negative battery cable.
2. Remove the radiator fan. See «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
3. Drain the cooling system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
4. Remove the air cleaner inlet tubes.
5. Disconnect the upper radiator hose (1).
6. Disconnect the lower radiator hose (2).
7. Disconnect the coolant recovery reservoir hose (1).
8. Disconnect the transmission cooler line (3) located on the right side of the radiator (automatic transmission only). See «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
9. Disconnect the transmission cooler line (1) located in the middle front of the vehicle (automatic transmission only). Using a suitable tool, grasp the radiator hold down clamps (2) and pull up to remove the clamps from the mounting holes.
10. Remove the condenser retaining bolts (1) from the radiator support.
11. Carefully lean the radiator back toward the engine.
12. Gently lift and remove the radiator from the vehicle.

External cleaning of the radiator fins can be accomplished by applying cold water and compressed air to the back (engine side) of the radiator. This method will help to flush the radiator of any trapped debris.

The radiator cooling fins should be checked for damage or deterioration. Inspect cooling fins to make sure they are not bent or crushed, these areas result in reduced heat exchange causing the cooling system to operate at higher temperatures. Inspect the plastic end tanks for cracks, damage, or leaks.

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). See «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
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. See «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
10. Install the air inlet tubes.
11. Refill the cooling system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
12. Connect the negative battery cable.
13. Start the engine and check for coolant leaks.
14. Recheck the coolant level.

Scheme 25

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 spring loaded pressure relief valve, and a spring loaded vacuum relief valve.

The pressure cap performs two tasks in a closed cooling system. The pressure cap must allow the cooling system to build pressure during engine operation, and allow the cooling system to loose pressure when not operating.

With the engine operating, the pressure cap must allow the cooling system to operate at higher than atmospheric pressure. This increased pressure raises the boiling point of the coolant, thereby allowing the cooling system to operate more efficiently. However, under excessive pressure, 110 kPa ± 14 kPa (16 psi ± 2 psi) the cooling system will overcome the spring pressure in the pressure cap and allow engine coolant to flow into the reservoir. This pressure relief will continue until the pressure is reduced and the spring in the pressure cap can return to its normally closed position.

With the engine not operating, the pressure cap must allow the cooling system to loose pressure and recover engine coolant. This recovery is accomplished through the use of a lighter spring in the pressure cap. As the hot engine coolant cools, it creates a vacuum in the cooling system. As this vacuum is created, it pulls the vacuum valve open and allows engine coolant to be pulled back into the engine from the coolant reservoir tank. This continues until the system pressure is equalized, and the vacuum valve is then returned to its normally closed position.

WARNING

There is no need to remove the pressure cap at any time except for the following purposes

1. Checking and adjusting the coolant freezing point.
2. Refilling system with new coolant.
3. Conducting service procedures.

Clean the radiator pressure cap using a mild soap and water only.

The water pump is a die cast aluminum housing with a swept vane impeller. It attaches directly to the timing chain cover. The pump is driven from the crankshaft by a single serpentine drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The water pump seals are lubricated by the engine coolant.

A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator, cooling system hoses, and heater core. The coolant absorbs the heat generated when the engine is operating. The water pump is driven by the crankshaft via the serpentine drive belt.

Scheme 26

Scheme 27

Scheme 28

Scheme 29

1. Disconnect the negative battery cable.
2. Drain the cooling system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
3. Remove the air cleaner inlet tubes (2).
4. Remove the engine cover (1). Grasp both corners of the engine cover, and pull up firmly.
5. Remove the radiator fan. See «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
6. Remove the accessory drive belt. See «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
7. Remove the belt tensioner. See «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
8. Disconnect the lower radiator hose (2).
9. Disconnect the coolant by-pass hose (1).
10. Remove the generator. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/charging-system/#charging-system) .
11. Remove the water pump pulley (2).
12. Remove the accessory drive belt idler pulley (1).
13. Remove the water pump retaining bolts and the water pump.

Scheme 30

Note. It is normal for the water pump to weep a small amount of coolant from the weep hole (black stain on water pump body). Do not replace the water pump if this condition exists. Replace the water pump if a heavy deposit or a steady flow of engine coolant is evident from the weep hole. This indicates a shaft seal failure and pump must be replaced. Be sure to perform a thorough analysis before replacing water pump.

Inspect and replace the water pump if it has any of the following defects

1. Damage or cracks on the pump body (1).
2. Coolant leaks; if the seal is leaking, this will be evident by traces of thick deposits of dried coolant draining from the pump weep hole. A thin black stain below pump weep hole/passage is considered normal operation (2).
3. Impeller rubs against the engine front cover (3).
4. Excessively loose or rough turning bearing (3).

Scheme 31

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 generator. Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/charging-system/#charging-system) .
5. Install the belt tensioner. See «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
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. Rotate the belt tensioner counterclockwise and install the accessory drive belt.
10. Release the belt tensioner and remove the wrench.
11. Install the radiator fan. See «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
12. 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.
13. Install the air cleaner inlet tubes (2).
14. Connect the negative battery cable.
15. Fill the cooling system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
16. Start the engine and check for coolant leaks.
17. Recheck the coolant level.

A single, serpentine style belt drives all of the engine accessories. The accessory drive includes an automatic tensioner, making adjustments unnecessary for the life of the belt.

Scheme 32

The accessory drive belt provides the link between the engine crankshaft and the engine accessories. Tension on the accessory drive belt is maintained by an automatic belt tensioner.

1. Crankshaft
2. A/C Compressor
3. Power Steering Pump
4. Idler Pulley
5. Generator
6. Water Pump
7. Tensioner

ACCESSORY DRIVE

TORQUE SPECIFICATIONS

REMOVAL

1. Remove the engine cover (1). Grasp both corners of the engine cover, and pull up firmly.
2. Remove the accessory drive belt. See «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
3. Remove the pulley from the accessory drive belt tensioner.
4. Remove the belt tensioner retaining bolts (1) and the belt tensioner (2).

Scheme 33

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. See «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
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 «INSPECTION»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
6. Inspect the pulleys for wear or damage.
7. Replace the accessory drive belt or pulleys as necessary.

Clean all foreign debris from the belt pulley grooves. The belt pulleys must be free of oil, grease, and coolant before installing the drive belt.

Scheme 34

Belt replacement is necessary for any or all of the following conditions

1. Excessive wear
2. Frayed cords
3. Severe glazing

The accessory drive belt may develop minor cracks across the ribbed side (1) due to reverse bending. These minor cracks are considered normal and acceptable. Parallel cracks (2) are not considered normal and should be cause for belt replacement.

Note. Do not use any type of belt dressing or restorer on the accessory drive belt.

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.

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

Scheme 35

Scheme 36

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.

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. See «OPERATION»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .

Scheme 37

Note. To service the front copper transmission cooler lines (5) the radiator must be removed. See 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. See «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
7. Check the transmission fluid level. Refer to «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/automatic-trans/#nag1-automatic-transmission-service-information) .

See also:
• REMOVAL
• STANDARD PROCEDURE
• STANDARD PROCEDURE