Thermostat

REMOVAL & INSTALLATION

1990–94 Vehicles

1. Disconnect the negative battery cable.
2. Drain the cooling system into a suitable container.
3. Disconnect the upper radiator hose and overflow hose from the thermostat housing.
4. Remove the thermostat housing and gasket.
5. Remove the thermostat taking note of its original position in the housing.

   Fig. 1: Exploded view of the thermostat and related components — 1990–94 vehicles

   Fig. 2: Install the thermostat so its flange seats tightly in the machined recess in the thermostat housing — 1990–94 1.8L engine

   Fig. 3: Proper installation of the thermostat — 1990–94 2.0L engine

   To install:

6. Install the thermostat so its flange seats tightly in the machined recess in the thermostat housing. Refer to its location prior to removal.
7. Use a new gasket and reinstall the thermostat housing. Tighten the housing mounting bolts to 12–14 ft. lbs. (17–20 Nm).
8. Attach the hoses and fill the system with coolant.
9. Connect the negative battery cable, run the vehicle until the thermostat opens and fill the radiator completely.
10. Once the vehicle has cooled, recheck the coolant level.

1995–98 Vehicles

1. Disconnect the negative battery cable.
2. Drain the cooling system into a suitable container.
3. For the 2.0L turbo engine, disconnect the air hose.
4. Matchmark the position of the upper or lower radiator hose for installation purposes.

   Fig. 4: Before disconnecting the radiator hose, matchmark for installation purposes — 1995–98 vehicles

5. For the 2.0L non-turbo engine, disconnect the radiator upper hose connection. Use a pair of pliers to unfasten the upper hose retaining clamp, then disconnect the hose

6. For the 2.0L turbo and 2.4L engines disconnect the radiator lower hose connector.
7. Unfasten the retaining bolt(s), then remove the water outlet or inlet fitting, as applicable.

   Fig. 5: Unfasten the thermostat housing retaining bolts

8. If equipped, remove gasket, then remove the thermostat from the vehicle.

   Fig. 6: Pull the fitting away, then remove the themostat from the vehicle

   Fig. 7: Exploded view of the thermostat and related components — 1995–98 vehicles

9. Thoroughly clean the gasket mating surfaces.

   To install:

10. Install the thermostat so that the jiggle valve is facing straight up and is aligned with the mark on the thermostat case as shown in the accompanying figure.

    Fig. 8: Position the thermostat in the housing

    Fig. 9: The thermostat must be installed in the proper position

    NOTE: Make sure that no oil sticks to the rubber ring of the thermostat. Also, make sure not to fold or scratch the ring when inserting the thermostat.

11. Position the water inlet or outlet fitting, then secure using the retaining bolt(s). For 2.0L non-turbo engines, tighten the bolt to 16 ft. lbs. (22 Nm). Tighten the bolts to 9.4 ft. lbs. (13 Nm) for 2.0L turbo and 2.4L engines.
12. Insert the radiator upper or lower hose as far as the projection of the water outlet or inlet fitting.
13. Align the mating marks on the radiator hose and hose clamp, then connect the radiator hose.

    Fig. 10: Insert the hose until it reaches the raised projection and align the mating marks

14. For the 2.0L turbo engine, connect the air hose.
15. Fill the cooling system with the proper type and amount of coolant.
16. Connect the negative battery cable, then start the engine and check for leaks. Check the coolant level, and add if necessary.