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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.

GC0163135Courtesy of CHRYSLER GROUP, LLC
  1. Clean the mating surfaces on the cylinder head and thermostat housing.
  2. Install a new thermostat housing gasket (1).
    GC0177082Courtesy of CHRYSLER GROUP, LLC
  3. Rotate the loop clamp (1) clockwise at least 45° away from the thermostat mounting surface.
    GC0176939Courtesy of CHRYSLER GROUP, LLC
  4. Pull the intake manifold upper support bracket (1) slightly away from the engine and install the thermostat housing (2).
    GC0176995Courtesy of CHRYSLER GROUP, LLC
  5. Rotate the loop clamp (1) back into position against the thermostat housing flange.
    GC0176959Courtesy of CHRYSLER GROUP, LLC
  6. Install the four thermostat housing bolts (2) hand tight.
  7. If removed, install the Engine Coolant Temperature (ECT) sensor (3) to the thermostat housing (1) and tighten to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0171601Courtesy of CHRYSLER GROUP, LLC
  8. Install the two bolts (2) to the intake manifold upper support bracket (1) hand tight.
  9. Tighten the intake manifold upper support bracket nuts (3) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  10. 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 torque specification. Refer to TECHNICAL SPECIFICATIONS .
  11. Connect and lock the Engine Coolant Temperature (ECT) sensor harness connector (4).
  12. Install the degas hose (5) to the thermostat housing and connect the quick-connect fitting.
    GC0165638Courtesy of CHRYSLER GROUP, LLC
  13. Bend the loop clamp end tab (1a) to secure the thermostat housing bolt (1b).
    GC0172072Courtesy of CHRYSLER GROUP, LLC
  14. Install the heater core inlet hose (1) to the thermostat housing and engage the quick-connect coupling.
    GC0159621Courtesy of CHRYSLER GROUP, LLC
  15. Install the shift cable (4) to the shift cable bracket (1) and engage the lock (3).
  16. Install the engine vacuum pump. Refer to PUMP, VACUUM, INSTALLATION .
    GC0171629Courtesy of CHRYSLER GROUP, LLC
  17. Install the upper radiator inlet hose (2) to the thermostat housing with the CLIC E®  type clamp using (special tool #10288, Pliers, Hose Clamp).
    GC0171271Courtesy of CHRYSLER GROUP, LLC
  18. Engage the wire harness retainer (1) to the upper radiator inlet hose at the thermostat housing.
  19. Install the Power Distribution Center (PDC). Refer to CENTER, POWER DISTRIBUTION (PDC), INSTALLATION .
  20. Install the battery tray and battery. Refer to TRAY, BATTERY, INSTALLATION .
  21. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
  22. Remove the support and lower the vehicle.
  23. Fill the cooling system. Refer to STANDARD PROCEDURE .
  24. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector to the negative battery cable.
  25. Run the engine until it reaches normal operating temperature. Check the cooling system for leaks and correct fluid level. Refer to STANDARD PROCEDURE .
  26. Install the engine cover.
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