REMOVAL
(1) Partially drain the cooling system below the
thermostat level.
(2) Disconnect throttle body air inlet hose, remove
air cleaner housing assembly (Refer to 9 - ENGINE/
AIR INTAKE SYSTEM - REMOVAL).
(3) Disconnect upper radiator hose from thermo-
stat housing.
(4) Remove thermostat housing attaching bolts in
the reverse order of the torque sequence (Fig. 16).
(5) Remove thermostat housing (Fig. 14).
(6) Remove thermostat from housing and discard
thermostat housing gasket.
INSTALLATION
CAUTION: Do not use a metal scraper to clean alu-
minum sealing surfaces, as damage to surfaces
may occur. Use only a plastic scraper and MoparT
Brake Parts Cleaner or the equivalent
(1) Clean both sealing surfaces using a plastic
scraper and Mopart Brake Parts Cleaner or the
equivalent. Take care not to scratch or gouge sealing
surfaces.
(2) Install new thermostat into thermostat hous-
ing.
(3) Install new thermostat housing gasket (Fig.
15).
(4) Install thermostat housing to chain case cover
(Fig. 14).
(5) Tighten thermostat housing bolts in the
sequence shown in (Fig. 16) to 11 N·m (95 in. lbs.).
(6) Connect upper radiator hose to thermostat
housing.
(7) Install air cleaner housing assembly, connect
throttle body air inlet hose (Refer to 9 - ENGINE/
AIR INTAKE SYSTEM - INSTALLATION).
(8) Refill cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE - FILLING
COOLING SYSTEM).
Fig. 14 Water Pump and Thermostat Housing
1 - THERMOSTAT HOUSING
2 - WATER PUMP
Fig. 15 Thermostat Housing and Gasket
1 - THERMOSTAT HOUSING
2 - THERMOSTAT
3 - GASKET
Fig. 16 Thermostat Housing Torque Sequence
ZB ENGINE 7 - 19
ENGINE COOLANT THERMOSTAT (Continued)
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