Installation

1. Clean mating areas of intake manifold and thermostat housing.





2. Install thermostat (spring side down) into recessed machined groove on intake manifold.
3. Install gasket on intake manifold and over thermostat.





4. Position the thermostat housing to the intake manifold. Note the word FRONT stamped on the housing. For adequate clearance, this must be placed towards the front of vehicle. The housing should be slightly angled forward after installation to intake manifold.
5. Install two housing-to-intake manifold bolts. Tighten bolts to 23 Nm (200 inch lbs.) torque.

CAUTION: Housing must be tightened evenly and thermostat must be centered into recessed groove in intake manifold. If not, it may result in a cracked housing, damag4ed intake manifold threads or coolant leak.

6. Install upper radiator hose to thermostat housing.
7. Air conditioned vehicles:
a. Install generator. Tighten bolts to 41 Nm (30 ft. lbs.).





b. Install support bracket (generator mounting bracket-to-intake manifold). Tighten bolts to 54 Nm (40 ft. lbs.) torque.





CAUTION: When installing the-serpentine accessory drive belt, the belt must be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction. Refer to illustration for correct engine belt routing. The correct belt with the correct length must be used.

c. Position the drive belt over all pulleys except the idler pulley (located between the generator and A/C compressor).





d. Attach a socket/wrench to the pulley mounting bolt of the automatic tensioner.
e. Rotate the socket/wrench clockwise. Place the belt over the idler pulley. Let tensioner rotate back into place. Remove wrench. Be sure belt is properly seated on all pulleys.





f. Install Jeep/Truck Engine Controller (JTEC).
8. Fill cooling system.
9. Connect negative battery cable to battery.
10. Start and warm engine. Check for leaks.
11. Install engine cover (if A/C equipped).