Breeze, Cirrus, Sebring Convertible and Sedan, Stratus Sedan, 1999-2005

Removal & Installation

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WARNING
Do not remove pressure cap or any hose with the system hot and under pressure because serious burns from coolant can occur.


NOTE
Always replace a thermostat that has failed. Do not attempt to free-up a stuck open thermostat.

2.0L & 2.4L Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
    CAUTION
    This operation must only be performed on a cold engine.

  4.  
  5. Drain cooling system to the thermostat level or below.
  6.  
  7. Remove or disconnect the following:

    Coolant recovery system hose
     
    Thermostat/engine outlet connector bolts
     
    Inlet hose and coolant elbow from thermostat housing
     

  8.  
  9. Remove thermostat assembly and clean sealing surfaces.

    Click image to see an enlarged view

    Fig. Thermostat and housing-2.0L and 2.4L engines

  10.  

To install:

  1. Place the new thermostat assembly into the engine outlet connector. Align air bleed with notch on the cylinder head.
  2.  
  3. Install engine outlet connector onto cylinder head and tighten bolts to 110 inch lbs. (12.5 Nm)
  4.  
  5. Connect the coolant recovery system hose.
  6.  
  7. Fill cooling system.
  8.  

  1. Drain cooling system to the thermostat level or below.
  2.  
  3. Remove the Coolant Recovery System (CRS) hose and thermostat/engine outlet connector bolts.
  4.  
  5. Remove the thermostat assembly, and clean sealing surfaces.

    Click image to see an enlarged view

    Fig. Thermostat assembly-2.0L engine



    Click image to see an enlarged view

    Fig. Thermostat assembly-2.4L engine

  6.  

To install:

  1. Place the new thermostat assembly into the engine outlet connector.
    1. Align air vent upward with notch on the cylinder head (2.0L engine).
    2.  
    3. Make sure spring side of thermostat faces cylinder head.
    4.  

  2.  
  3. Install the engine outlet connector onto cylinder head and tighten bolts to 110 inch lbs. (12.5 Nm)
  4.  
  5. Connect the Coolant Recovery System (CRS) hose.
  6.  
  7. Fill cooling system.
  8.  

2.5L & 3.0L Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
    CAUTION
    This operation must only be performed on a cold engine.

  4.  
  5. Drain cooling system to the thermostat level or below.
  6.  
  7. Remove or disconnect the following:

    Coolant recovery system hose
     
    Thermostat/engine outlet connector bolts
     
    Inlet hose and coolant elbow from thermostat housing
     

  8.  
  9. Remove thermostat assembly and clean sealing surfaces.

    Click image to see an enlarged view

    Fig. Thermostat and housing-2.5L and 3.0L engines

  10.  

To install:

  1. Install thermostat into the recess in the thermostat housing.
  2.  
  3. Install inlet elbow and tighten the bolts to 168 inch lbs. (19 Nm)
  4.  
  5. Fill cooling system.
  6.  

2.7L Engine



  1. Disconnect negative cable from remote jumper terminal.
  2.  
  3. Drain cooling system.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the right front wheel and belt splash shield.
  8.  
  9. Remove the accessory drive belts.
  10.  
  11. Remove the 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 the oil dipstick and tube. Plug hole in oil pan where dipstick tube mounts with water tight stopper.
    NOTE
    If hole for dipstick tube in oil pan is not plugged, coolant will enter oil pan. Serious engine damage can occur.

  20.  
  21. Remove the remaining alternator mounting bolts. Remove alternator.
  22.  
  23. Disconnect hoses at thermostat housing.
  24.  
  25. Remove the thermostat housing bolts.
  26.  
  27. Remove the thermostat and housing.

    Click image to see an enlarged view

    Fig. Air bleed valve (1) and thermostat housing (2) 2.7L-engine

  28.  

To install:

  1. Clean gasket sealing surfaces.
  2.  
  3. Install the thermostat and gasket into the thermostat housing.
    1. Make sure spring side of thermostat faces the engine side.
    2.  
    3. Install the thermostat with the air bleed valve located at the 12 o'clock position.
    4.  

  4.  
  5. Install the thermostat and housing to cylinder block. Tighten attaching bolts to 105 inch lbs. (12 Nm).
  6.  
  7. Connect hoses at thermostat housing.
  8.  
  9. Install the alternator and attaching bolts.
  10.  
  11. Clean residual coolant from area around hole for dipstick.
  12.  
  13. Remove the plug in oil pan and install the engine oil dipstick tube.
  14.  
  15. Reconnect AC clutch and AC pressure sensor connectors.
  16.  
  17. Reconnect alternator connectors.
  18.  
  19. Raise and safely support the vehicle.
  20.  
  21. Install the accessory drive belts.
  22.  
  23. Install the belt splash shield and right front wheel.
  24.  
  25. Lower vehicle.
  26.  
  27. Reconnect negative battery cable.
  28.  
  29. Fill cooling system.
  30.  

 
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