Removal

WARNING: DO NOT LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM THE COOLANT CAN OCCUR.

NOTES:
^ Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.
^ If the thermostat is being replaced, be sure that the replacement is the specified thermostat for the vehicle model and engine type.
^ Factory installed thermostat housings on all engines are installed on-a gasket with an anti-stick coating. This will aid in gasket removal and clean up.

1. Disconnect negative battery cable at battery.
2. Drain cooling system until coolant level is below thermostat.
3. If equipped with air conditioning:
a. Remove engine cover from vehicle interior.





b. Remove the support bracket (generator mounting bracket-to-intake manifold) located near the rear of generator.





c. The generator must be partially removed. Drive belts on all engines are equipped with a spring loaded automatic belt tensioner. Remove the generator drive belt as follows:
d. Attach a socket/wrench to the pulley mounting bolt of the automatic tensioner.
e. Rotate the tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt.
f. Remove belt from generator pulley.
g. Remove the two generator mounting bolts. Do not remove any wiring at generator.
h. Remove generator. Position generator to gain access for thermostat gasket removal.





i. Remove the three Jeep/Truck Engine Controller (JTEC) mounting bolts and remove JTEC. Do not disconnect 60-way connector from JTEC. Lay JTEC aside.





WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL NUMBER 6094. SNAP-ON CLAMP TOOL NUMBER HPC-20, OR EQUIVALENTS MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.





CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter.

4. Remove upper radiator hose clamp. Remove upper radiator hose at thermostat housing.
5. Position the wiring harness (behind the thermostat housing) to gain access to thermostat housing.





6. Remove thermostat housing mounting bolts, thermostat housing, gasket and thermostat. Discard old gasket.