How to Change the Thermostat in a Plymouth Voyager
- 1). Connect the battery cable from the negative terminal. Then isolate it to avoid accidental contact with the terminal while installing the thermostat. Drain the cooling system until the coolant level is below that of the thermostat.
- 2). Loosen the bolts on the thermostat housing. Pull the upper radiator hose then take off the housing bolts and remove the housing. Disconnect the thermostat. Remove the old gasket and throw it away.
- 3). Clean any dirt, debris or gasket material from the housing and the mating surfaces. Soak the new gasket in clean water to create a good seal, then set it on the water box surface. Center the thermostat over the new gasket.
- 4). Inspect the threads on the housing bolts to make sure they are clean and free of any corrosion caused by exposure to coolant. Use a small wire brush to clean the threads as needed.
- 5). Install the thermostat into the housing recess and set the housing in place. Apply torque to the bolts as follows: 105 inch lbs. on the 3.0L engine; 21 foot pounds on the 3.3L and 3.8L engines.
- 6). Reconnect the upper radiator hose and secure the clamp. Connect the negative battery cable to the terminal and tighten the bolt. Fill the cooling system with a 50/50 mix of water and ethylene glycol antifreeze until the radiator is full.
- 7). Start the engine and run it until the thermostat opens. Fill the coolant overfill tank as needed. Pressure test the system for leaks.
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