2.4L Multi Air: Removal

1. Remove the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION COVER, ENGINE, REMOVAL AND INSTALLATION COVER, ENGINE, REMOVAL AND INSTALLATION .
2. Remove the battery and battery tray. Refer to TRAY, BATTERY, REMOVAL AND INSTALLATION .
3. Drain the cooling system. Refer to STANDARD PROCEDURE .

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4. Loosen the clamp and remove the radiator hose (1) from the thermostat housing.

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5. Disconnect the Engine Coolant Temperature (ECT) sensor wire harness connector (1).
6. Disconnect the quick-connect coupling and remove the coolant hose (2) from the thermostat housing

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7. Disconnect the quick-connect coupling and remove the degas hose (1) from the thermostat housing.

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8. Release the lock tab (1a) and remove the bolt (1b) securing the coolant tube to the thermostat housing.

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9. Remove the bolt and loosen the nuts (1a) from the intake manifold upper support bracket (1b).
   NOTE:

   The bracket (1b) can not be removed at this time. Loosening the nuts (1a) will allow the bracket (1b) to be repositioned so the thermostat housing can be removed.

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   NOTE:

   A swivel socket or ratcheting wrench may be required to remove the lower rear bolt.

10. Remove the bolts (1) securing the thermostat housing.

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11. Remove the thermostat housing (1).

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12. Remove and discard the thermostat housing gasket (1).

INSTALLATION 

1. Clean the gasket mating surfaces.

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2. Install a NEW  thermostat housing gasket (1).

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3. Rotate the loop clamp (1) clockwise at least 45° away from the thermostat mounting surface.

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4. Pull the intake manifold upper support bracket (1) slightly away from the engine and install the thermostat housing (2).

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5. Rotate the loop clamp (1) back into position against the thermostat housing flange.

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6. Install the four thermostat housing bolts (1) hand tight.

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7. Install the fasteners (1a) to the intake manifold upper support bracket (1b). Securely tighten the fasteners and previously installed thermostat housing bolts in a criss-cross pattern to the proper torque specifications. Refer to TECHNICAL SPECIFICATIONS .

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8. Bend the loop clamp end tab (1a) to secure the thermostat housing bolt (1b).

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9. Install the degas hose (1) to the thermostat housing and connect the quick-connect fitting.

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10. Install the coolant hose to the thermostat housing and engage the quick-connect coupling (2).
11. Connect and lock the Engine Coolant Temperature (ECT) sensor wire harness connector (1).

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12. Install the radiator hose (1) to the thermostat housing and securely tighten the clamp.
13. Install the battery tray and battery. Refer to TRAY, BATTERY, REMOVAL AND INSTALLATION .
14. Fill the cooling system. Refer to STANDARD PROCEDURE .
15. Install the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION COVER, ENGINE, REMOVAL AND INSTALLATION COVER, ENGINE, REMOVAL AND INSTALLATION .
16. Start engine and check for leaks.
17. Run the engine until it reaches normal operating temperature. Check the cooling system for correct fluid level. Refer to STANDARD PROCEDURE .