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Engine Cooling System: Engine: Thermostat: Installation: 2.4L

CAUTION:

The Thermostat and housing is serviced as an assembly. Do not remove the thermostat from the housing, damage to the thermostat may occur.

Fig 1: Thermostat Housing Gasket
GC0163135Courtesy of CHRYSLER GROUP, LLC
  1. Clean the mating surfaces on the engine block and thermostat housing.
  2. Install a new thermostat housing gasket (1).
    Fig 2: Thermostat Housing, Engine Coolant Temperature Sensor & Bolts
    GC0171104Courtesy of CHRYSLER GROUP, LLC
  3. Pull the intake manifold upper support bracket slightly away from the engine and install the thermostat housing (1) with two bolts (2) hand tight.
  4. If removed, install the Engine Coolant Temperature (ECT) sensor (3) to the thermostat housing (1) and tighten to the proper specification. Refer to SPECIFICATIONS .
    Fig 3: Loop Clamp & Bolt
    GC0171106Courtesy of CHRYSLER GROUP, LLC
  5. Position the loop clamp (1) and install the thermostat housing bolt (2) hand tight.
    Fig 4: Intake Manifold Upper Support Bracket, Bolts, Nuts, Hose & Connector
    GC0171601Courtesy of CHRYSLER GROUP, LLC
  6. Install the two bolts (2) to the intake manifold upper support bracket (1) hand tight.
  7. Tighten the intake manifold upper support bracket nuts (3) to the proper specification. Refer to SPECIFICATIONS .
  8. Tighten the intake manifold upper support bracket bolts (2) and the three other previously installed thermostat housing bolts in a criss-cross pattern to the proper specification. Refer to SPECIFICATIONS .
  9. Connect and lock the Engine Coolant Temperature (ECT) sensor harness connector (4).
  10. Install the degas hose (5) to the thermostat housing and connect the quick-connect fitting.
    Fig 5: Coolant Tube To Thermostat Housing Lock Tab & Bolt
    GC0165638Courtesy of CHRYSLER GROUP, LLC
  11. Bend the loop clamp end tab (1a) to secure the thermostat housing bolt (1b).
    Fig 6: Heater Hoses
    GC0172072Courtesy of CHRYSLER GROUP, LLC
  12. Install the heater core inlet hose (1) to the thermostat housing and engage the quick-connect coupling.
    Fig 7: Shifter Cable & Shifter Bracket
    GC0159621Courtesy of CHRYSLER GROUP, LLC
  13. Install the shift cable (4) to the shift cable bracket (1) and engage the lock (3).
  14. Install the engine vacuum pump. Refer to PUMP, VACUUM, INSTALLATION .
    Fig 8: Block Heater Power Cord & Radiator Hoses
    GC0171629Courtesy of CHRYSLER GROUP, LLC
  15. Install the upper radiator inlet hose (2) to the thermostat housing with the CLIC E®  type clamp using (special tool #10288, Pliers, Hose Clamp).
    Fig 9: Wire Harness Retainer
    GC0171271Courtesy of CHRYSLER GROUP, LLC
  16. Engage the wire harness retainer (1) to the upper radiator inlet hose at the thermostat housing.
  17. Install the Power Distribution Center (PDC). Refer to CENTER, POWER DISTRIBUTION (PDC), INSTALLATION .
  18. Install the battery tray and battery. Refer to TRAY, BATTERY, INSTALLATION .
  19. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
  20. Remove the support and lower the vehicle.
  21. Fill the cooling system. Refer to STANDARD PROCEDURE .
  22. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector to the negative battery cable.
  23. Run the engine until it reaches normal operating temperature. Check the cooling system for leaks and correct fluid level. Refer to STANDARD PROCEDURE .
  24. Install the engine cover.
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