Avenger 2008

Removal & Installation

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2.4L Engine



Primary Thermostat

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Partially drain cooling system.
  2.  
  3. Remove air filter housing.
  4.  
  5. Disconnect coolant hose (1) from inlet housing (2).

    Click image to see an enlarged view

    Fig. Disconnect coolant hose (1) from inlet housing (2)

  6.  
  7. Remove inlet housing bolts (3).
  8.  
  9. Remove thermostat assembly, and clean sealing surfaces.
  10.  

To install:

  1. Position thermostat into the water plenum, aligning air bleed with the location notch on inlet housing.
  2.  
  3. Install inlet housing onto coolant adapter. Tighten bolts to 79 inch lbs. (9 Nm).
  4.  
  5. Connect coolant hose.
  6.  
  7. Install air filter housing.
  8.  
  9. Fill cooling system
  10.  

Secondary Thermostat

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Partially drain cooling system.
  2.  
  3. Remove air filter housing.
  4.  
  5. Disconnect coolant hoses (1) from rear of coolant adapter (2).

    Click image to see an enlarged view

    Fig. Disconnect coolant hoses (1) from rear of coolant adapter (2)

  6.  
  7. Remove radiator hose (3).
  8.  
  9. Remove radiator hose (4) from front of coolant adapter (2).
  10.  
  11. Remove coolant adapter mounting bolts.
  12.  
  13. Carefully slide coolant adapter off water pump inlet tube and remove coolant adapter (2) and secondary thermostat.
  14.  

To install:

  1. Position thermostat into the cylinder head.
  2.  
  3. Inspect the water pump inlet tube O-rings for damage before installing the tube in the coolant adapter.
  4.  
  5. Replace O-ring as necessary.
  6.  
  7. Lubricate O-rings with soapy water.
  8.  
  9. Position coolant adapter on water pump inlet tube and cylinder head.
  10.  
  11. Install coolant adapter mounting bolts. Tighten bolts to 159 inch lbs. (18.1 Nm).
  12.  
  13. Connect front coolant hose.
  14.  
  15. Connect two rear coolant hoses.
  16.  
  17. Connect radiator hose.
  18.  
  19. Install air filter housing.
  20.  
  21. Fill cooling system
  22.  

2.7L Engine



Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Disconnect negative cable from remote jumper terminal.
  2.  
  3. Drain cooling system.
  4.  
  5. Raise vehicle on hoist.
  6.  
  7. Remove right front wheel and belt splash shield.
  8.  
  9. Remove accessory drive belts.
  10.  
  11. Remove lower alternator mounting bolt.
  12.  
  13. Lower vehicle.
  14.  
  15. Disconnect alternator electrical connectors.
  16.  
  17. Disconnect AC clutch and AC pressure sensor electrical connectors. Reposition wiring harness.
  18.  
  19. Remove oil dipstick and tube. Plug hole in oil pan where dipstick tube mounts with water tight stopper.
    WARNING
    If hole for dipstick tube in oil pan is not plugged, coolant will enter oil pan. Serious engine damage can occur.

  20.  
  21. Remove remaining alternator mounting bolts. Remove alternator.
  22.  
  23. Remove radiator hose tube mounting bolt (3).

    Click image to see an enlarged view

    Fig. Remove radiator hose tube mounting bolt (3)

  24.  
  25. Disconnect hose clamps at thermostat housing.
  26.  
  27. Remove thermostat housing bolts.
  28.  
  29. Remove thermostat and housing.
  30.  

To install:

  1. Clean gasket sealing surfaces.
    NOTE
    Install thermostat with the bleed valve located at the 12 o'clock position.

  2.  
  3. Install thermostat and gasket into the thermostat housing.
  4.  
  5. Install thermostat and housing to cylinder block. Tighten attaching bolts to 105 inch lbs. (12 Nm).
  6.  
  7. Install radiator hose tube to thermostat and housing. Connect hose clamps at thermostat housing. Install radiator hose tube mounting bolt.
  8.  
  9. Install alternator and attaching bolts.
    CAUTION
    Before removing plug in oil pan, clean residual coolant from area.

  10.  
  11. Remove plug in oil pan and install engine oil dipstick tube.
  12.  
  13. Reconnect AC clutch and AC pressure sensor connectors.
  14.  
  15. Reconnect alternator connectors.
  16.  
  17. Raise vehicle on hoist.
  18.  
  19. Install accessory drive belts.
  20.  
  21. Install belt splash shield and right front wheel.
  22.  
  23. Lower vehicle.
  24.  
  25. Reconnect negative battery cable.
  26.  
  27. Fill cooling system.
  28.  

3.5L Engine



Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Disconnect negative battery cable.
  2.  
  3. Drain cooling system.
  4.  
  5. Disconnect upper radiator hose from thermostat housing (1).

    Click image to see an enlarged view

    Fig. Disconnect upper radiator hose from thermostat housing (1)

  6.  
  7. Remove thermostat housing bolts.
  8.  
  9. Remove housing, thermostat, and gasket.
  10.  

To install:

  1. Clean gasket sealing surfaces.
  2.  
  3. Install thermostat and gasket into thermostat housing.
    NOTE
    For ease of installation, install bolts in housing for thermostat and gasket retention.

  4.  
  5. Install thermostat and housing to Intake manifold. Tighten bolts to 105 inch lbs. (12 Nm).
  6.  
  7. Connect radiator hoses and install hose clamp.
  8.  
  9. Refill cooling system.
  10.  
  11. Connect negative cable.
  12.  

 
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