Engine Cooling System: Engine: Thermostat: Removal: 2.4L

CAUTION:

Do not loosen radiator draincock with system hot and pressurized. Serious burns from coolant can occur.

CAUTION:

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

Remove the engine cover.
Disconnect and isolate the battery negative cable.
Raise and support the vehicle.
Remove the belly pan.
Drain the cooling system.
Lower vehicle.
Remove the battery.
Remove the battery tray assembly
Refer to TRAY, BATTERY, REMOVAL .
Remove the brake vacuum pump
Refer to PUMP, VACUUM, REMOVAL .
Remove the three bolts that attach the PDC to the body.
Position the PDC to the side to allow for thermostat housing removal.

Fig 1: Intake Manifold Upper Support Bracket, Bolts & Nuts
Courtesy of CHRYSLER GROUP, LLC
Remove the intake manifold upper support bracket (1) bolts (3).
Looses but do not remove the bracket nuts (2).
NOTE:
The bracket can not be removed at this time, loosening the nuts allow the necessary movement for the thermostat housing to be removed.

Fig 2: Thermostat Housing, Hose Outlets/Inlets & Coolant Temperature Sensor
Courtesy of CHRYSLER GROUP, LLC
Remove the coolant recovery bottle return hose (1).
Disconnect the engine coolant temperature sensor harness connector (2).
Disconnect the forward most shift cable from the transmission lever.
Remove the heater core supply hose (4). (special tool #10288, Pliers, Hose Clamp)
Using Special Tool 10288, release the clamps at the heater core return (5) and thermostat outlet (7).
Remove the heater core return hose (5).
Remove the thermostat outlet hose (7).
Remove the thermostat housing bolts (3).
Remove the thermostat housing (6) from the engine.