Chrysler Caravan/Voyager/Town and Country 1996-1999

Thermostat

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REMOVAL & INSTALLATION



2.4L Engine

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Place a large drain pan under the radiator drain plug. Allow the cooling system to sufficiently cool down before opening the drain plug to avoid personal injury. Drain the coolant to below the thermostat level.
  4.  
  5. Disconnect the upper radiator hose at the thermostat housing.
  6.  
  7. Remove the thermostat housing bolts and coolant outlet connector of the thermostat housing.
  8.  
  9. Remove the thermostat assembly from the vehicle and discard. Discard the old thermostat gasket.
  10.  



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Fig. Fig. 1: Thermostat installation-2.4L engine

To install:
  1. Clean all gasket mating surfaces.
  2.  
  3. Install the new thermostat in the correct position. If equipped, align the air bleed valve on top of thermostat to the vent recess in the water box (engine side) of the thermostat housing.
  4.  
  5. Dip the new new gasket in clean water and install on the water box surface of the thermostat housing.
  6.  
  7. Install the thermostat housing over the gasket and thermostat, making sure the thermostat is in correct position.
  8.  
  9. Install the thermostat housing bolts and torque to 20 ft. lbs. (28 Nm).
  10.  
  11. Reconnect the radiator hose. Tighten the radiator hose clamp.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Fill and bleed the engine cooling system.
  16.  
  17. Pressure test for leaks.
  18.  

3.0L, 3.3L and 3.8L Engines

See Figures 2, 3, 4, 5, 6 and 7

  1. Disconnect the negative battery cable.
  2.  
  3. Place a drain pan under the radiator drain and drain the cooling system to just below the thermostat level. Close the drain.
  4.  
  5. Remove the upper radiator hose from the thermostat housing, then remove the housing.
  6.  
  7. Remove the thermostat and discard the gasket.
  8.  



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Fig. Fig. 2: Thermostat installation detail-3.0L engine



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Fig. Fig. 3: Thermostat installation detail-3.3L and 3.8L engines

To install:
  1. Clean the housing mating surfaces.
  2.  
  3. Dip the new gasket in clean water and place it on the water box surface.
  4.  
  5. Center the thermostat on the gasket, in the water box.
  6.  



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Fig. Fig. 4: Remove the radiator hose from the waterneck by loosening the hose clamp ...

  1. Make certain the bolt threads are clean. Threaded bolt holes exposed to coolant are subject to corrosion and should be cleaned with a small wire brush or correct size thread-cutting tap. Install the housing, making sure the thermostat is still in the recess, and tighten the retaining bolts to 105 inch lbs. (12 Nm) for 3.0L engine or to 21 ft. lbs. (28 Nm) for 3.3L and 3.8L engines. Reconnect the upper radiator hose and tighten the hose clamp.
  2.  
  3. Connect the negative battery cable.
  4.  
  5. Fill and bleed the engine cooling system with a clean 50 / 50 mixture of ethylene glycol antifreeze and water.
  6.  



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Fig. Fig. 5: Lift the waterneck housing off of the lower intake manifold, then ...



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Fig. Fig. 6: ... remove the thermostat out of its mounting flange

  1. Make sure the radiator is full and start the vehicle.
  2.  


CAUTION
Do not remove the radiator cap once the vehicle is warm. Coolant is under pressure and may cause scalding or personal injury.

  1. Run the vehicle until the thermostat opens. Check the coolant level in the overflow tank and fill if necessary.
  2.  
  3. Pressure test for leaks.
  4.  



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Fig. Fig. 7: Make sure to clean the waterneck before installation

 
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