Cherokee, Grand Cherokee, 1999-2005

Removal & Installation

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


NOTE
Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. If thermostat is being replaced, be sure that replacement is specified thermostat for vehicle model and engine type.

  1. Drain the coolant from the radiator until the level is below the thermostat housing.
    WARNING
    Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp, such as special clamp tool (number 6094). Snap on clamp tool (Number HPC-20) may be used for larger clamps. Always wear safety glasses when servicing constant tension clamps.


    CAUTION
    A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter.

  2.  
  3. Remove radiator upper hose and heater hose at thermostat housing.
  4.  
  5. Disconnect wiring connector at engine coolant temperature sensor.
  6.  
  7. Remove thermostat housing mounting bolts, thermostat housing, gasket and thermostat. Discard old gasket.
  8.  
  9. Clean the gasket mating surfaces.
  10.  

To install:

  1. Install the replacement thermostat so that the pellet, which is encircled by a coil spring, faces the engine. All thermostats are marked on the outer flange to indicate the proper installed position.
  2.  
  3. Observe the recess groove in the engine cylinder head.
  4.  
  5. Position thermostat into this groove with arrow and air bleed hole on outer flange pointing up.
  6.  
  7. Install replacement gasket and thermostat housing.
    CAUTION
    Tightening the thermostat housing unevenly or with the thermostat out of its recess may result in a cracked housing.

  8.  
  9. Tighten the housing bolts to 15 ft. lbs.(20 Nm).
  10.  
  11. Install hoses to thermostat housing.
  12.  
  13. Install electrical connector to coolant temperature sensor.
  14.  
  15. Be sure that the radiator drain cock is tightly closed. Fill the cooling system to the correct level with the required coolant mixture.
  16.  
  17. Start and warm the engine, and check for leaks.
  18.  

3.7L & 4.7L Engines




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


NOTE
Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. If thermostat is being replaced, be sure that replacement is specified thermostat for vehicle model and engine type.

  1. Disconnect negative battery cable at battery.
  2.  
  3. Drain cooling system.
  4.  
  5. Raise vehicle on hoist.
  6.  
  7. Remove splash shield.
  8.  
  9. Remove lower radiator hose clamp and lower radiator hose at thermostat housing.
  10.  
  11. Remove thermostat housing mounting bolts, thermostat housing and thermostat.
  12.  

To install:

  1. Clean mating areas of timing chain cover and thermostat housing.
  2.  
  3. Install thermostat (spring side down) into recessed machined groove on timing chain cover.
  4.  
  5. Position thermostat housing on timing chain cover.
  6.  
  7. Install two housing-to-timing chain cover bolts. Tighten bolts to 115 inch lbs. (13 Nm).
    CAUTION
    Housing must be tightened evenly and thermostat must be centered into recessed groove in timing chain cover. If not, it may result in a cracked housing, damaged timing chain cover threads or coolant leaks.

  8.  
  9. Install lower radiator hose on thermostat housing.
  10.  
  11. Install splash shield.
  12.  
  13. Lower vehicle.
  14.  
  15. Fill cooling system.
  16.  
  17. Connect negative battery cable to battery.
  18.  
  19. Start and warm the engine. Check for leaks.
  20.  

5.7L Engines




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


NOTE
Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. If thermostat is being replaced, be sure that replacement is specified thermostat for vehicle model and engine type.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the radiator hose clamp and radiator hose at the thermostat housing .
  6.  
  7. Remove the thermostat housing mounting bolts , thermostat housing and thermostat.
  8.  

To install:

  1. Position the thermostat and housing on the front cover.
  2.  
  3. Install thermostat housing bolts . Tighten the bolts to 112 inch lbs. (13 Nm).
  4.  
  5. Install the radiator hose onto the thermostat housing .
  6.  
  7. Fill the cooling system.
  8.  
  9. Connect negative battery cable.
  10.  
  11. Start and warm the engine. Check for leaks.
  12.  

  1. Siphon power steering reservoir.
  2.  
  3. Remove the air intake tube.
  4.  
  5. Remove the drive belt.
  6.  
  7. Disconnect the supply hose at the pump .
  8.  
  9. Disconnect the pressure line at the pump.
  10.  
  11. Remove the three pump mounting bolts.
  12.  

To install:

  1. Install pulley on pump if removed.
  2.  
  3. Install 3 pump mounting bolts and tighten to 20 ft. lbs. (27 Nm).
  4.  
  5. Install the pressure hose on the pump and tighten the nut to 21 ft. lbs. (28 Nm).
  6.  
  7. Reconnect the supply hose at the pump .
  8.  
  9. Install the drive belt.
  10.  
  11. Install the air intake tube.
  12.  
  13. Fill the system with power steering fluid.
  14.  
  15. Bleed the hydraulic fan system using a scan tool.
  16.  

 
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