Engine Cooling System: Other Dodge Dart PF

COOLING SYSTEM COMPONENTS

The cooling system consists of

1. Electric cooling fan
2. Radiator
3. A coolant recovery system
4. Thermostat
5. Water pump
6. Transmission oil cooler (ATX only)
7. Radiator pressure cap
8. Coolant
9. Water pump
10. Hoses and hose clamps
11. A core support mounted coolant crossover tube (2.0L/2.4L only)
12. Thermostat housing assembly
13. Afterrun pump and hoses assembly (1.4L Turbocharged only)

Scheme 28

A new style hose clamps called the CLIC E® and the CLIC R® are used to ensure a more even distribution of the clamping force.

Scheme 29

CLIC E®

Used for most applications that have a large variation of expansion and contraction. Equipped with a spring. The clamp is able to adjust while ensuring proper tension. If the clamp is removed for repairs. It can be reused.

Note. Always use Special tool 10288 Pliers when removing and installing the hose clamps to avoid damaging the clamp. The Click E type clamp can be reused if the clamp is in serviceable condition.

Scheme 30

CLIC R®

Used for most applications that require a capacity reserve designed to compensate for the tolerance ranges of the hoses and spigots to be tightened. If the clamp needs to be removed for repairs. The clamp must be replaced to ensure proper fitting to that component.

Note. If the hose or the fitting is not replaced, the same Click R type clamp can be re-used given it is installed in the same orientation and same location on the hose. If the fitting or the hose is replaced, the Click R type clamp MUST be replaced.

Scheme 31

It is highly recommended that the use of a CLIC style pliers (Miller tool # (special tool #10288, Pliers, Hose Clamp)) be used for proper installation and removal of the CLIC® clamps. The use of specific tools for the clamp, will allow it to be reused.

The use of non CLIC® style pliers (screwdrivers, vice grips, channel locks, etc.) may damage the clamp and the clamp must be replaced.

CLIC© HOSE CLAMP PLIERS - USAGE

When CLIC© style clamps are used. It requires that miller tool (special tool #10288, Pliers, Hose Clamp) for proper installation and removal.

Scheme 32

Installation of the hose clamp requires the flat blade of the pliers to rest against the latch lock side of the clamp. The notched end of the pliers will position to the protruded guide on the latch side. Squeeze the pliers until a CLICK sound is heard.

Scheme 33

Removal of the hose clamp requires the notched end of the pliers to rest against the latch side of the clamp. Squeezing the pliers will cause the hook of the latch lock to ride up the beveled edging of the notched side, releasing itself from the lock.

AERATION

If coolant level drops below a certain point, aeration will occur drawing air into the water pump resulting in the following

1. High reading shown on the temperature gauge.
2. Loss of coolant flow through the heater core.
3. Corrosion in the cooling system.
4. Transmission oil will become hotter (automatic transmission equipped vehicles).
5. Water pump seal may run dry, increasing the risk of premature seal failure.
6. Combustion gas leaks into the coolant can also cause the above problems.

DEAERATION

As air is removed from the cooling system, it gathers in the coolant recovery container. This pressure is released into the atmosphere through the pressure valve located in the radiator pressure cap when pressure reaches 96 - 124 kPa (14 - 18 psi). This air is replaced with coolant from the coolant recovery container.

Note. Deaeration does not occur at engine idle, higher engine speeds are required. Normal driving will deaerate cooling system.

To effectively deaerate the system, multiple thermal cycles of the system may be required.

Establish what driving conditions caused the complaint. Abnormal loads on the cooling system such as the following may be the cause

1. Prolonged idle
2. Very high ambient temperature
3. Slow traffic
4. Traffic jams
5. High speed or steep grades
6. Debris on front of the grill or the cooling module that is restricting airflow

Driving techniques that avoid overheating are

1. Idle with A/C off when temperature gauge is at end of normal range.
2. Increasing engine speed up to 2000 RPM with transmission in park or neutral for more airflow is recommended.

RECENT SERVICE OR ACCIDENT REPAIR

Determine if any recent service has been performed on vehicle that may affect the cooling system. This may be

1. Engine adjustments (incorrect timing)
2. Slipping engine accessory drive belt(s)
3. Brakes (possibly dragging)
4. Changed parts. Incorrect water pump or pump rotating in wrong direction due to belt not correctly routed
5. Reconditioned radiator or cooling system refilling (possibly under filled or air trapped in system).
6. Service to electrically controlled viscous fan clutch

Note. If investigation reveals none of the previous items as a cause for an engine overheating complaint. Refer to the COOLING SYSTEM. Refer to DIAGNOSIS AND TESTING .

Scheme 34

A leak detection additive is available through the parts department that can be added to cooling system. The additive is highly visible under ultraviolet light (black light) (1). Pour one ounce of additive into cooling system. Place heater control unit in HEAT position. Start and operate the engine until the radiator upper hose is warm to the touch. Aim the commercially available black light tool at the components to be checked. If leaks are present, the black light will cause the additive to glow a bright green color.

The black light can be used in conjunction with a pressure tester to determine if any external leaks exist.

PRESSURE TESTER METHOD

The engine should be at normal operating temperature. Recheck the system cold if the cause of coolant loss is not located during the warm engine examination.

Carefully remove the radiator pressure cap from the filler neck and check the coolant level. Push down on the cap to disengage it from the stop tabs. Wipe the inside of the filler neck and examine the lower inside sealing seat for nicks, cracks, paint, dirt and solder residue. Inspect the radiator-to- reserve/overflow tank hose for internal obstructions. Insert a wire through the hose to be sure it is not obstructed.

Inspect the cams on the outside of the filler neck. If the cams are damaged, seating of the pressure cap valve and tester seal will be affected.

Attach pressure tester ((special tool #7700, Tester, Cooling System) or an equivalent) to radiator filler neck.

Operate the tester pump to apply 103.4 kPa (15 psi) pressure to the system. If the hoses enlarge excessively or bulges while testing, replace as necessary. Observe the gauge pointer and determine the condition of the cooling system according to following criteria

Holds Steady: If the pointer remains steady for two minutes, serious coolant leaks are not present in system. However, there could be an internal leak that does not appear with normal system test pressure. If it is certain that coolant is being lost and leaks cannot be detected, inspect for interior leakage or perform Internal Leakage Test. Refer to INTERNAL LEAKAGE INSPECTION .

Drops Slowly: Indicates a small leak or seepage is occurring. Examine all of the connections for seepage or slight leakage with a flashlight. Inspect the radiator, hoses, gasket edges and heater. Seal the small leak holes with a Sealer Lubricant (or equivalent). Repair the leak holes and inspect the system again with pressure applied.

Drops Quickly: Indicates that serious leakage is occurring. Examine the system for external leakage. Block side panels are embossed to highlight core plugs. Remove embossed noise panels to inspect and or repair core plugs. If leaks are not visible, inspect for internal leakage.

CHEMICAL CLEANING

If visual inspection indicates the formation of sludge or scaly deposits, use a radiator cleaner (Mopar® Radiator Kleen or equivalent) before flushing. This will soften scale and other deposits and aid the flushing operation.

STANDARD PROCEDURE - COOLANT AIR EVACUATION-2.0L/2.4L

Note. The preferred way to remove air from the cooling system in vehicles equipped with a Tigershark engine is to use Chrysler PSE (Pentastar Service Equipment) (special tool #399-550000, Tool, UView Airlift™ Cooling System Refill) If this tool is not available, Special tool 8195A MUST BE USED and the procedure addressing the proper use of that tool is described below.

Evacuating or purging air from the cooling system involves the use of a pressurized air operated vacuum generator. The vacuum created allows for a quick and complete coolant refilling while removing any airlocks present in the system components.

Note. To avoid damage to the cooling system, ensure that no component would be susceptible to damage when a vacuum is drawn on the system.

Note. The service area where this procedure is performed should have a minimum shop air requirement of 80 PSI (5.5 bar) and should be equipped with an air dryer system.

Note. For best results, the radiator should be empty.

1. Refer to the Chrysler PSE (Pentastar Service Equipment) (special tool #399-550000, Tool, UView Airlift™ Cooling System Refill) or equivalent tool's operating manual for specific assembly steps.
2. Choose an appropriate adapter cone that will fit the reservoir tank neck.
3. Attach the adapter cone (2) to the vacuum gauge (1).
4. Make sure the vacuum generator/venturi ball valve (3) is closed and attach an airline hose (2) (minimum shop air requirement of 80 psi/5.5 bar) to the vacuum generator/venturi (1).
5. Position the adaptor cone/vacuum gauge assembly into the reservoir tank neck. Ensure that the adapter cone is sealed properly.
6. Connect the vacuum generator/venturi (2) to the positioned adaptor cone/vacuum gauge assembly (1).
7. Open the vacuum generator/venturi ball valve. NOTE: Do not bump or move the assembly as it may result in loss of vacuum. Some radiator overflow hoses may need to be clamped off to obtain vacuum.
8. Let the system run until the vacuum gauge shows a good vacuum through the cooling system. Refer to the tool's operating manual for appropriate pressure readings. NOTE: If a strong vacuum is being created in the system, it is normal to see the radiator hoses collapse.
9. Close the vacuum generator/venturi ball valve.
10. Disconnect the vacuum generator/venturi (1) and airline from the adaptor cone/vacuum gauge assembly (2).
11. Wait approximately 20 seconds, if the pressure readings do not move, the system has no leaks. If the pressure readings move, a leak could be present in the system and the cooling system should be checked for leaks and the procedure should be repeated. View typical
12. Place the tool's suction hose (2) into the coolant's container. NOTE: Ensure there is a sufficient amount of coolant, mixed to the required strength/protection level available for use. For best results and to assist the refilling procedure, place the coolant container at the same height as the radiator filler neck. Always draw more coolant than required. If the coolant level is too low, it will pull air into the cooling system which could result in airlocks in the system.
13. Pre-fill the tool suction hose (2) with coolant.
14. Connect the tool's suction hose (2) to the adaptor cone/vacuum gauge assembly (3). NOTE: View typical
15. Open the suction hose's ball valve to begin refilling the cooling system.
16. When the vacuum gauge reads zero and the proper level is reached in the coolant bottle, the system is filled.
17. Close the suction hose's ball valve and remove the suction hose from the adaptor cone/vacuum gauge assembly.
18. Remove the adaptor cone/vacuum gauge assembly from the coolant bottle neck.
19. Install the coolant bottle cap.
20. With heater control unit in the HEAT position, start the engine.
21. Run the engine at 3, 000 RPM to help purge the air back to the bottle.
22. Look for flow at the coolant bottle return hose inlet. CAUTION: If there is no flow present at the coolant bottle return hose inlet, you must repeat the procedure beginning at step 1 or engine damage may occur.
23. After engine has reached normal operating temperature, shut engine off and allow it to cool. Use the radiator vent valve to purge any remaining air from the radiator.
24. Add coolant to the coolant bottle as necessary. Only add coolant to the container when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion. Add necessary coolant to raise container level to the FULL mark after each cool down period.
25. Once the appropriate coolant level is achieved, install the cap.

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

1. If using special Tool (special tool #8195A, Funnel)
2. Select the appropriate fitting extension (3) and locking ring (2) and attach to the fill neck of the cooling system.
3. Make sure the adapter seal fits firmly against the inside of the fill neck base to ensure a good seal. After the extension and locking ring are installed, make sure the extension can not be moved. This will confirm a good seal.
4. Select a length of clear hose that is long enough to reach from the radiator fill vent outlet to the coolant bottle.
5. Attach the hose (2) to the radiator fill vent outlet (3) and place the other end in the fill funnel (1). NOTE: The hose attachment will aid in air removal.
6. Disconnect the coolant bottle return hose at the bottle end of the hose. Cap the coolant bottle nipple.
7. Attach the funnel (1) to the extension (3) and fill with coolant.
8. Rotate the radiator vent valve handle (1) counterclockwise approximately 180°. NOTE: The valve will need to opened enough to allow air and coolant to escape into the attached hose. DO NOT remove the valve (1) from the radiator (3).
9. Add coolant to the funnel. NOTE: Make sure a sign of coolant is present in the clear hose. It may be necessary to add more coolant to the funnel to accomplish this. NOTE: The higher the fluid level, the better the bleed results. Continue to add coolant until it is free of bubbles and settles at a level. NOTE: Make sure the funnel does not become empty during the fill and bleed procedure.
10. Release the heater core return hose quick connect (1) by squeezing the two release tabs. Wait until a stream of coolant is present. NOTE: Venting air from the heater core return hose will help the water pump to prime.
11. Attach the quick connect. Make sure the fitting is completely seated.
12. Locate the cylinder head drain plug (3). It is located on the rear face of the head just forward of the thermostat housing (1).
13. Using a 6 mm hex wrench (2), loosen the drain plug 5 full turns.
14. Once fluid starts to seep from the area between the plug and the cylinder head, observe for fluid that is free of air bubbles. Once the fluid is clear of air, tighten the plug.
15. Install the stopper (4) into the funnel base. The stopper will prevent the fluid that is left in the funnel from spilling out when separated from the extension.
16. Rotate the radiator valve (1) clockwise to the closed position.
17. Fill coolant recovery container to the FULL mark.
18. Remove the funnel, extension and locking ring.
19. Remove the cap from the coolant bottle nipple.
20. Attach the coolant bottle return hose to the bottle with a NEW CLIC E® clamp.
21. Top off the coolant bottle to the FULL line and install the cap.
22. Start the engine and accelerate from idle to 3000 RPM while an assistant observes the coolant bottle return hose inlet at the top of the bottle. CAUTION: If there is no flow present at the coolant bottle return hose inlet, you must repeat the procedure beginning at step 1 or engine damage may occur. While the engine RPM's are up, the fluid will push through the hose and into the bottle. Once the fluid is free of air pockets/bubbles and the hose becomes warm, allow the engine to return to idle.
23. Run the engine until the thermostat opens, upper radiator hose will be warm to the touch.
24. Pinch off the upper radiator hose for a minimum of 30 seconds and as long as 1 minute while running the engine at 3000 RPM. NOTE: Forcing coolant through the oil cooler will purge air trapped in the oil cooler lines.
25. Allow the engine to return to idle. Shut the engine off. Allow the cooling system to settle and cool down.
26. Remove the coolant bottle cap.
27. Open the radiator vent valve (1) until a solid flow of coolant is preset in the hose.
28. Once coolant is evident in the hose, close the valve (1).
29. Remove the clear hose from the fitting.
30. Fill the coolant bottle to the FULL line. Install the cap.
31. Check for leaks.

1.4L

1. Position the serpentine belt (3) around the pulleys.
2. Rotate the tensioner center bolt (2) counterclockwise
3. Position the belt around the tensioner pulley.
4. Verify the belt is properly positioned around all of the pulleys.
5. Install the air cleaner assembly (1).

2.0L/2.4L

1. Install the accessory drive belt (5).
2. Install the inner wheel splash shield.
3. Install the right front wheel.
4. Connect the negative battery.
5. Install the engine cover.

Scheme 41

Correct drive belt tension is required to ensure optimum performance of the belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, loss of air conditioning performance, reduced generator output rate, and greatly reduced belt life.

It is not necessary to adjust belt tension. The tensioner maintains correct accessory drive belt tension at all times.

Note. The belt and tensioner can be removed from the top of the vehicle. Hoisting of the vehicle is not necessary.

1. Remove the air cleaner assembly. Refer to «AIR CLEANER, REMOVAL»(ref-646216-S32691632802014072800000) . CAUTION: Do not let the tensioner arm snap back to the freearm position, severe damage may occur to the tensioner.
2. Rotate the belt tensioner center bolt (2) counterclockwise.
3. Remove the serpentine belt (3).
4. Remove the tensioner mounting bolt (1).
5. Remove the tensioner from the vehicle.

1. Disconnect and isolate the battery negative cable.
2. Raise and support the vehicle.
3. Remove the belly pan.
4. Remove the right front wheel.
5. Remove the five push pins from the forward end of the right wheel liner.
6. Remove the three screws that attach the forward end of the right wheel liner to the fender.
7. Pull the forward end of the wheel liner free and position it rearward.
8. Release the tensioner (7) by rotating the center bolt counterclockwise.
9. Remove the accessory drive belt (5).
10. Remove the tensioner lower bolt from below.
11. Lower the vehicle.
12. Using a 12 inch socket extension, access the tensioner upper bolt from between the catalytic converter and the engine block.
13. Remove the upper bolt.
14. The tensioner can be removed from below.

1. Position the tensioner into position.
2. Align the belt tensioner tabs to the holes on the accessory bracket.
3. Install the mounting bolt (1). Tighten bolt (1) to 26 N.m (19 ft. lbs.).
4. Rotate the tensioner pulley bolt (2) counterclockwise and install the accessory drive belt (3).

1. Position the tensioner into place through the wheel well opening.
2. Loosely install the lower bolt.
3. Lower the vehicle.
4. Install the upper bolt. Tighten the upper and lower bolts to 28 N.m (21 ft. lbs)
5. Install the accessory drive belt. Refer to «BELT, SERPENTINE, INSTALLATION»(ref-646235-S37622997972014072800000) .
6. Install the inner wheel splash shield.
7. Install the right front wheel.
8. Connect the negative battery.
9. Install the engine cover.

COOLANT PERFORMANCE

The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows

Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol, but this is not suitable for use in a cooling system. Water also freezes at a higher temperature, boils at a lower temperature and allows corrosion.

100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F).

50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water.

OAT coolant is a Life of the Engine coolant. Maintenance of the cooling system is not required unless a repair has been made with loss of coolant or the coolant has been contaminated.

COOLANT SELECTION AND ADDITIVES

The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar® Antifreeze/Coolant (glycol base coolant with corrosion inhibitors called OAT, for Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution.

1. Raise vehicle.
2. Remove the lower engine cover.
3. Drain the coolant into a clean container.
4. Remove power cord connector (4) from block heater (3).
5. Remove screw (2) on block heater (3). Remove heater assembly (3).

1. Remove the engine cover.
2. Unplug the power cord from block heater (1).
3. Pull the tab (2) away from the cylinder block.
4. Slide the block heater (3) to the right and out of the bore.
5. Remove the heater from the vehicle.

1. Thoroughly clean cylinder block core hole and block heater seat.
2. Insert block heater assembly (3) into the block.
3. With block heater fully seated, tighten bolt (2) to 3 N.m (27 in. lbs.).
4. Connect power cord to block heater (2).

1. Insert the block heater (3) into the block bore.
2. Push the heater to the left until the tab (2) catches onto the block.
3. Plug the block heater cord (1) into the heater.
4. Install the engine cover.

Scheme 42

Scheme 43

1. Drain the cooling system.
2. Remove the timing belt. Refer to «BELT, TIMING»(ref-646215-S26794497442014072800000) .
3. Remove the screws (1) and the nut (2) securing the water pump to the engine block.
4. Remove the water pump(2) from the engine block by lightly prying at the upper tab (1) located on the pump assembly.

Scheme 44

Scheme 45

1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
2. Remove the right front tire.
3. Remove the belly pan
4. Remove the front closeout panel.
5. Drain the coolant.
6. Remove the 3 fender screws and the 3 push pins from the forward portion of the right front wheel liner. This will allow the liner to be positioned rearward to
7. Remove the serpentine belt.
8. Remove the 3 water pump pulley bolts (1).
9. Remove the water pump pulley (2).
10. Remove the water pump bolts (3).
11. Remove the water pump (4) and the water pump gasket (8).
12. Inspect the water pump housing (6) for impeller contact.
13. Clean the mating surface.
14. Remove the water pump.

Scheme 46

1. Clean the mating surfaces.
2. Apply a strip of silicone sealant to the contact surfaces between the water pump and the engine block.
3. Position pump onto the engine block.
4. Install the mounting bolts and nut. Tighten to 10 N.m (89 in. lbs.)
5. Rotate pump by hand to check for freedom of movement.
6. Install the timing belt (1). Refer to «BELT, TIMING, INSTALLATION»(ref-646215-S23117408282014072800000) .
7. Evacuate air and fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .

1. Position the water pump (4) into position with a new gasket (8).
2. Install the water pump bolts (3). Tighten the bolts to 24 N.m (18 ft. lbs.)
3. Install the water pump pulley (2).
4. Install the pulley bolts (1). Tighten the bolts to 9 N.m (80 in lbs.).
5. Install the serpentine belt. Refer to «BELT, SERPENTINE, INSTALLATION»(ref-646235-S37622997972014072800000) .
6. Install the belly pan and closeout panel. Refer to «BELLY PAN, INSTALLATION»(ref-646214-S07994234782014072800000) .
7. Install the 3 fender screws and the 3 push pins in the right front wheel liner.
8. Install the tire/wheel assembly.

Scheme 47

1. On the 1.4L turbocharged engine, there is an after-run pump (4) located on the right inner fender, bolted to the front of the shock tower (1). The after-run pump has an electrical connector (3) and two coolant hose connections (2).

Scheme 48

Scheme 49

1. Remove the engine cover.
2. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
3. Disconnect and isolate the battery cables.
4. Remove the battery. Refer to «BATTERY, REMOVAL»(ref-646227-S35480669362014072800000) .
5. Remove the battery tray. Refer to «TRAY, BATTERY, REMOVAL»(ref-646227-S29548343982014072800000) .
6. Remove the coolant recovery bottle return hose (1).
7. Remove the lower radiator hose.
8. Remove the oil cooler return hose (3).
9. Disconnect the engine coolant temperature sensor (4) harness connector.
10. Remove the heater supply hose (1).
11. Remove the engine coolant temperature sensor (4).
12. Remove the thermostat mounting bolts (2).
13. Remove the thermostat from the engine block and discard gasket seal (1).
14. Remove the temperature sensor.

2.4L

Scheme 50

Scheme 51

1. Remove the engine cover.
2. Disconnect and isolate the battery negative cable.
3. Raise and support the vehicle.
4. Remove the belly pan.
5. Drain the cooling system.
6. Lower vehicle.
7. Remove the battery.
8. Remove the battery tray assembly. Refer to «TRAY, BATTERY, REMOVAL»(ref-646227-S29548343982014072800000) .
9. Remove the brake vacuum pump. Refer to «PUMP, VACUUM, REMOVAL»(ref-646217-S40863078532014072800000) .
10. Remove the three bolts that attach the PDC to the body.
11. Position the PDC to the side to allow for thermostat housing removal.
12. Remove the intake manifold upper support bracket (1) bolts (3).
13. Looses but do not remove the bracket nuts (2). NOTE: The bracket can not be removed at this time, loosening the nuts allow the necessary movement for the thermostat housing to be removed.
14. Remove the coolant recovery bottle return hose (1).
15. Disconnect the engine coolant temperature sensor harness connector (2).
16. Disconnect the forward most shift cable from the transmission lever.
17. Remove the heater core supply hose (4). (special tool #10288, Pliers, Hose Clamp)
18. Using Special Tool 10288, release the clamps at the heater core return (5) and thermostat outlet (7).
19. Remove the heater core return hose (5).
20. Remove the thermostat outlet hose (7).
21. Remove the thermostat housing bolts (3).
22. Remove the thermostat housing (6) from the engine.

1. Clean the mating surfaces on the engine block and thermostat housing.
2. Install new gasket seal (1) onto the thermostat housing.
3. Install the engine coolant temperature sensor (4).
4. Install the thermostat housing mounting bolts (2). Tighten bolts to 9 N.m (80 in. lbs.).
5. Install the heater supply hose (3).
6. Connect the temperature sensor wire harness connector to the ECT sensor (4).
7. Install the coolant recovery bottle return hose quick connect (1).
8. Install the upper radiator hose to the thermostat inlet.
9. Install the oil cooler pipe. Tighten the bolt to 9 N.m (80 in. lbs.).
10. Install the battery tray. Refer to «TRAY, BATTERY, INSTALLATION»(ref-646227-S37644486382014072800000) .
11. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .

1. Clean the mating surfaces on the engine block and thermostat housing.
2. Install new gasket seal onto the thermostat housing.
3. Pull the manifold bracket (1) slightly away from the engine to allow the housing to be installed.
4. Position the thermostat housing (6) in place.
5. Install the four housing bolts. Tighten bolts to 9 N.m (80 in. lbs.). NOTE: Make sue the left lower bolt passes through the Adele clamp that secures the lower tube assembly to the housing.
6. Connect the cable to the transmission lever.
7. Install the thermostat outlet hose (7).
8. Install the heater core supply (4) and return hoses (5). (special tool #10288, Pliers, Hose Clamp)
9. Use Special Tool 10288 to secure the clamp at the heater core return hose (5) and the thermostat outlet (7).
10. Install the engine coolant temperature sensor (2). Plug in the connector.
11. Install the coolant recovery bottle return hose (1).
12. Tighten the bracket bolts (3) and nuts (2) to 9 N.m (80 in. lbs.).
13. Install the three PDC bolts. Tighten to 9 N.m (80 in. lbs.)
14. Install the battery tray. Refer to «TRAY, BATTERY, INSTALLATION»(ref-646227-S37644486382014072800000) .
15. Install the battery. Tighten the nut to 5 N.m (44 in. lbs.).
16. Install the brake vacuum pump. Refer to «PUMP, VACUUM, INSTALLATION, 2.0L»(ref-646216-S27800279482014072800000) or «PUMP, VACUUM, INSTALLATION, 2.4L»(ref-646217-S10081487522014072800000) .
17. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
18. Install the engine cover.