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    2004 Chrysler Crossfire 3.2L SFI SOHC 6cyl

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    405 N COLLEGE ST
    (479) 443-4043

    CLOSED Open at 7:30 AM

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    Use Code: SEECLEAR

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    Zephyr 2006, Fusion & Milan 2006-2007, MKZ 2007

    Removal & Installation

    Print

    2.3L Engine



    1. Raise and safely support the vehicle.
    2.  
    3. Drain the cooling system.
    4.  
    5. Loosen the 3 coolant pump pulley bolts.
    6.  
    7. Remove the accessory drive belt.
    8.  
    9. Remove the 3 bolts and the coolant pump pulley.
      1. To install, tighten to 20 Nm (15 lb-ft).
      2.  

    10.  
    11. Remove the 3 bolts and the coolant pump.
    12.  
    13. Remove and discard the O-ring seal.
      1. To install, tighten to 10 Nm (89 lb-in).

        Click image to see an enlarged view

        Fig. Exploded view of the water pump-2.3L engine

      2.  

    14.  

    To install:

    1. To install, reverse the removal procedure.
    2.  
    3. Lubricate the O-ring seal with clean engine coolant.
    4.  
    5. Fill and bleed the cooling system
    6.  

    3.0L Engines



    1. Raise and safely support the vehicle.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove the coolant pump belt.
    6.  
    7. Using Special tool 303-S455, or equivalent, remove the coolant pump drive pulley.

      Click image to see an enlarged view

      Fig. Using Special tool 303-S455, or equivalent, remove the coolant pump drive pulley

    8.  
    9. Disconnect the heater hose from the coolant pump.
    10.  
    11. Disconnect the coolant pump-to-engine hose and position aside.
    12.  
    13. Remove the 3 bolts from the coolant pump assembly.
    14.  
    15. Reposition the coolant pump-to-thermostat housing hose clamp and remove the coolant pump and hose as an assembly.

      Click image to see an enlarged view

      Fig. View of the water pump and related compoents-3.0L engine

    16.  

    To install:

    1. Connect the coolant pump-to-thermostat housing hose and reposition the clamp.
    2.  
    3. Position the coolant pump assembly and install the 3 bolts:
      1. Tighten to 10 Nm (89 lb-in).
      2.  
      3. Tighten the 3 bolts an additional 90 degrees.
      4.  

    4.  
    5. Connect the coolant pump-to-engine hose and the heater hose.
      NOTE
      Install the coolant pump drive pulley flush with the end of the camshaft.

    6.  
    7. Using Special tools 211-185 and 303-S455, or equivalent, install the coolant pump drive pulley.

      Click image to see an enlarged view

      Fig. Using Special tools 211-185 and 303-S455, or equivalent, install the coolant pump drive pulley

    8.  
    9. Install the coolant pump belt.
    10.  
    11. Fill and bleed the cooling system.
    12.  

    3.5L Engine




    WARNING
    During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

    1. Raise and safely support the vehicle.
    2.  
    3. Drain the cooling system.
    4.  
    5. Loosen the exhaust flexible pipe clamp and disconnect the 2 exhaust hangers.
    6.  
    7. Remove the 4 nuts, the exhaust flexible pipe and the Y-pipe as an assembly. Discard the nuts and the gasket.
    8.  
    9. Remove the LH and RH catalytic converters. Refer to the Exhaust Manifold procedure for more information on catalytic converter removal.
    10.  
    11. If equipped, remove the heat shield and disconnect the block heater electrical connector.
    12.  
    13. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow the coolant to drain from the cylinder block into a suitable container.
    14.  
    15. Remove the LH cylinder block drain plug. Allow the coolant to drain from the cylinder block into a suitable container.
    16.  
    17. Remove the engine front cover.
    18.  
    19. Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT) assemblies as shown in the accompanying illustration.
      NOTE
      The special tool will hold the camshafts in the Top Dead Center (TDC) position.



      Click image to see an enlarged view

      Fig. Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT) assemblies as shown

    20.  
    21. Install the special tool onto the flats of the LH camshafts.
      NOTE
      The special tool will hold the camshafts in the TDC position.



      Click image to see an enlarged view

      Fig. Install the special tool onto the flats of the camshafts-left side shown, right side similar

    22.  
    23. Install the special tool onto the flats of the RH camshafts.
    24.  
    25. Remove the 3 bolts and the RH VCT housing.

      Click image to see an enlarged view

      Fig. Remove the 3 bolts and the VCT housing-right side shown, left side similar

    26.  
    27. Remove the 3 bolts and the LH VCT housing.
    28.  
    29. Remove and discard the VCT housing seals.
    30.  
    31. Remove the 2 bolts and the primary timing chain tensioner.

      Click image to see an enlarged view

      Fig. Remove the 2 bolts and the primary timing chain tensioner

    32.  
    33. Remove the primary timing chain tensioner arm.
    34.  
    35. Remove the 2 bolts and the lower LH primary timing chain guide.
    36.  
    37. Remove the primary timing chain.
    38.  
    39. Remove the 2 bolts and the upper LH primary timing chain guide.

      Click image to see an enlarged view

      Fig. Remove the 2 bolts and the upper LH primary timing chain guide

    40.  
    41. Remove the RH primary timing chain guide lower bolt.
      NOTE
      The RH primary timing chain guide must be repositioned to allow the water pump to be removed.

    42.  
    43. Loosen the RH primary timing chain guide upper bolt. Rotate the guide and tighten the bolt.

      Click image to see an enlarged view

      Fig. Loosen the RH primary timing chain guide upper bolt. Rotate the guide and tighten the bolt

    44.  
    45. Remove the 8 bolts and the water pump.
    46.  
    47. Thoroughly clean and inspect all mating surfaces.
    48.  

    To install:

    1. Install the water pump and the 8 bolts. Tighten in the sequence shown to 10 Nm (89 inch lbs.).

      Click image to see an enlarged view

      Fig. Water pump bolt tightening sequence

    2.  
    3. Loosen the RH primary timing chain guide upper bolt.
    4.  
    5. Position the RH primary timing chain guide and install the lower bolt. Tighten the 2 bolts to 10 Nm (89 inch lbs.).
    6.  
    7. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.

      Click image to see an enlarged view

      Fig. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket

    8.  
    9. Install the upper LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 inch lbs.).
    10.  
    11. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 inch lbs.).
    12.  
    13. Install the primary timing chain tensioner arm.
    14.  
    15. Reset the primary timing chain tensioner, as follows:
      1. Rotate the lever counterclockwise.
      2.  
      3. Using a soft-jawed vise, compress the plunger.
      4.  
      5. Align the hole in the lever with the hole in the tensioner housing.
      6.  
      7. Install a suitable lock pin.
        NOTE
        It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner.



        Click image to see an enlarged view

        Fig. Rotate the lever counterclockwise. Using a soft-jawed vise, compress the plunger. Align the hole in the lever with the hole in the tensioner housing, then insert a lock pin

      8.  
      9. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 inch lbs.).
      10.  
      11. Remove the lock pin.

        Click image to see an enlarged view

        Fig. Install the primary tensioner, secure with the 2 bolts, then remove the lock pin

      12.  

    16.  
    17. As a post check, verify correct alignment of all timing marks.
    18.  
    19. Install new VCT housing seals.
      WARNING
      Make sure the dowels on the VCT housing are fully engaged in the cylinder head prior to tightening the bolts.

    20.  
    21. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 inch lbs.).
      WARNING
      Make sure the dowels on the VCT housing are fully engaged in the cylinder head prior to tightening the bolts.



      Click image to see an enlarged view

      Fig. Install the left side VCT housing and tighten the bolts in the sequence shown

    22.  
    23. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 inch lbs.).

      Click image to see an enlarged view

      Fig. Install the right side VCT housing and tighten the bolts in the sequence shown

    24.  
    25. Install the engine front cover.
    26.  
    27. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten the cylinder block drain plug to 20 Nm (15 ft. lbs.). Tighten the block heater to 41 Nm (30 ft. lbs.).
      NOTE
      Make sure that the block heater wiring is routed and secured away from rotating or hot components, or damage to the wiring can occur.

    28.  
    29. If equipped, connect the block heater electrical connector and install the heat shield.
    30.  
    31. Install the LH cylinder block drain plug. Tighten to 20 Nm (15 ft. lbs.) plus an additional 180 degrees.
    32.  
    33. Install the LH and RH catalytic converters.
    34.  
    35. Position the Y-pipe assembly in place and install the 4 nuts. Tighten to 40 Nm (30 ft. lbs.).
    36.  
    37. Install the 2 exhaust hangers and tighten the exhaust clamp. Tighten to 40 Nm (30 ft. lbs.).
    38.  
    39. Fill the engine with clean engine oil.
    40.  
    41. Fill and bleed the cooling system
    42.  

     
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