1. Drain the coolant from the radiator until the level is below the thermostat housing. 2. Remove radiator upper hose and heater hose at thermostat. 3. Disconnect wiring connector at engine coolant temperature sensor. 4. Remove thermostat housing mounting bolts, thermostat housing, gasket and thermostat. See Fig. 13 . 5. Remove and discard old gasket. Fig. 13: Removing Thermostat Courtesy of CHRYSLER CORP. Installation 1. Clean the gasket mating surfaces. 2. Install the replacement thermostat so that the pellet, which is encircled by a coil spring, faces the engine. All thermostats are marked on the outer flange to indicate the proper installed position. 3. Observe the recess groove in the engine cylinder head. See Fig. 14 . Position thermostat into this groove with arrow and air bleed hole on outer flange pointing up. 4. Install replacement gasket and thermostat housing. See Fig. 13 . 5. Tighten the housing bolts. See TORQUE SPECIFICATIONS . 6. Install hoses to thermostat housing. 7. Install electrical connector to coolant temperature sensor. 8. Be sure that the radiator draincock is tightly closed. Fill the cooling system to the correct level with the required coolant mixture. 9. Start and warm the engine. Check for leaks. WARNING: DO NOT loosen the radiator draincock with the system hot and pressurized. Serious burns form the coolant can occur. WARNING: Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp, such as Special Clamp Tool (6094), or Snap-On Clamp Tool (HPC-20) CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. NOTE: Do not waste coolant. If solution is clean, drain the coolant into a clean container for reuse. CAUTION: Tightening the thermostat housing unevenly or with the thermostat out of its recess may result in a cracked housing.
Hole(pellet) goes at 12:00 o'clock position. Torque is 15 ft. lbs.
Sunday, November 22nd, 2009 AT 9:01 AM