Chrysler Cirrus/Stratus/Sebring/Avenger/Breeze 1995-1998

Thermostat

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REMOVAL & INSTALLATION



2.0L DOHC Engine

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the upper radiator hose from the water outlet.
  6.  
  7. Remove the thermostat housing.
  8.  
  9. Remove the thermostat, taking note of its original position in the housing.
  10.  



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Fig. Fig. 1: Exploded view of the thermostat installation-2.0L DOHC engine

To install:
  1. Thoroughly clean the thermostat housing and cylinder head mating surfaces.
  2.  
  3. Install the thermostat so its flange seats tightly in the machined recess in the thermostat housing. Refer to its position prior to removal.
  4.  
  5. Clean the bolt threads well. Bolts that thread into openings exposed to the coolant may have a build-up of rust and corrosion. Clean threads are necessary to effectively tighten bolts. Install the water outlet to the thermostat housing with a new gasket. Tighten the housing mounting bolts to 16 ft. lbs. (22 Nm). Do not overtighten, or the thermostat housing and/or water outlet may crack.
  6.  
  7. Connect the lower hose and fill the system with coolant.
  8.  
  9. Connect the negative battery cable. With the radiator cap off, start the engine and allow it to run until the thermostat opens. Add coolant as necessary to fill the radiator completely. Watch the coolant temperature gauge ( if equipped) for signs of overheating.
  10.  
  11. Once the vehicle has cooled, recheck the coolant level in the radiator and the coolant overflow tank.
  12.  

2.0L SOHC and 2.4L DOHC Engines

See Figures 2 and 3

  1. Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with an insulator grommet, which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
  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 level below that of the thermostat.
  4.  
  5. Disconnect the coolant recovery hose and radiator hose.
  6.  
  7. Remove the thermostat housing bolts.
  8.  
  9. Remove the thermostat assembly from the vehicle.
  10.  



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Fig. Fig. 2: Thermostat removal and installation-2.0L engine



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Fig. Fig. 3: Thermostat removal and installation-2.4L engine

To install:
  1. Thoroughly clean all sealing surfaces.
  2.  
  3. Install the replacement thermostat and align the air bleed opening with the notch on the cylinder head. Install the thermostat housing using a new gasket.
  4.  
  5. Reinstall the thermostat housing bolts and tighten to 110 inch lbs. (12.5 Nm).
  6.  
  7. Reconnect the coolant recovery hose and radiator hose. Tighten the radiator hose clamp.
  8.  
  9. Reconnect the negative battery cable to the remote terminal at the shock tower.
  10.  
  11. Refill and bleed the engine cooling system.
  12.  
  13. Pressure test for leaks.
  14.  

2.5L Engine

See Figures 4 through 10

  1. Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
  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.  



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Fig. Fig. 4: Move the hose clamp down away from the thermostat housing



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Fig. Fig. 5: Pull the lower coolant hose off of the thermostat housing



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Fig. Fig. 6: Remove the 3 thermostat housing fasteners



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Fig. Fig. 7: Pull out the thermostat housing from the engine



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Fig. Fig. 8: Remove the thermostat from the engine

  1. Remove the inlet radiator hose hose and coolant elbow from the thermostat housing.
  2.  
  3. Remove the thermostat housing bolts.
  4.  
  5. Remove the thermostat assembly from the vehicle and discard.
  6.  

To install:
  1. Thoroughly clean all sealing surfaces.
  2.  



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Fig. Fig. 9: When installing a new thermostat, make sure that the small bleed hole is positioned at the top



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Fig. Fig. 10: Before installing a new thermostat, clean the flange surface of the housing

  1. Install the thermostat into the recess of the thermostat housing. Be sure to install the new thermostat with the bleed vent hole positioned upward.
  2.  
  3. Reinstall the thermostat housing using a new gasket. Reinstall the thermostat housing bolts and tighten to 133 inch lbs. (13 Nm).
  4.  
  5. Reconnect the inlet radiator hose to the thermostat housing and tighten the radiator hose clamp.
  6.  
  7. Reconnect the negative battery cable.
  8.  
  9. Refill and bleed the engine cooling system.
  10.  
  11. Pressure test the cooling system for leaks.
  12.  

 
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