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Home >> Jeep >> 1996 >> Grand Cherokee Limited, 5.2 Y >> Repair and Diagnosis >> External Pages >> Different car >> Section 178 (5.2L V8 Gas - VIN [Y]) >> Removal & Installation >> Thermostat >> Installation - 3.9L/5.2L Engine

Installation - 3.9L/5.2L Engine

WARNING: This page is about a different car, the 1995 Jeep Grand Cherokee, 1995 Dodge Ram Wagon, 1995 Dodge Ram Van, 1995 Dodge Pickup, and 1995 Dodge Dakota. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean mating areas of intake manifold and thermostat housing.
  2. Install thermostat (spring side down) into recessed machined groove on intake manifold (Fig 1).
  3. Install gasket on intake manifold and over thermostat (Fig 1)
  4. Position thermostat housing to intake manifold. Note the word FRONT stamped on housing (Fig 2). For adequate clearance, this must  be placed towards front of vehicle. The housing is slightly angled forward after installation to intake manifold.
    Fig 1: Thermostat - 3.9L/5.2L Engine
    G00486695Courtesy of CHRYSLER CORP.
    Fig 2: Thermostat Position - 3.9L/5.2L Engine
    G00486696Courtesy of CHRYSLER CORP.
  5. Install two housing-to-intake manifold bolts. Tighten bolts to 23 N.m (200 in. lbs.) torque.
    6. 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, damaged intake manifold threads or coolant leak.
  6. Install upper radiator hose to thermostat housing.
  7. Air conditioned vehicles:
    1. Install generator. Tighten bolts to 41 N.m (30 ft. lbs.).
    2. Install support bracket (generator mounting bracket-to-intake manifold) (Figure). Tighten bolts to 54 N.m (10 ft. lbs.) torque.
      3. CAUTION: When installing the serpentine accessory drive belt, belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to (Fig 3) for correct 3.9L/5.2L engine belt routing. The correct belt with correct length must be used.
      Fig 3: Belt Routing - 3.9L/5.2L Engine
      G00486697Courtesy of CHRYSLER CORP.
    3. Position drive belt over all pulleys except  idler pulley (located between generator and A/C compressor).
    4. Attach a socket/wrench to pulley mounting bolt of automatic tensioner (FigureFigure).
    5. Rotate socket/wrench clockwise. Place belt over idler pulley. Let tensioner rotate back into place. Remove wrench. Be sure belt is properly seated on all pulleys.
  8. Fill cooling system.
  9. Connect negative battery cable to battery.
  10. Start and warm the engine. Check for leaks.
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