How to Change the Thermostat in a '99 Dodge Intrepid 2.7

The thermostat on the 1999 Dodge Intrepid 2.7-liter is located on the engine block just behind the alternator. Replacement of the thermostat requires removing the alternator and power steering belt as well as the alternator itself. The procedure is performed mainly from under the vehicle, so the vehicle has to be lifted and the splash shield removed.

Instructions

Open the vehicle hood and support it with the hood prop rod. Put on safety glasses. Ensure the engine is completely cool and remove the coolant pressure cap from the coolant reservoir. Disconnect the negative battery cable from the battery jumper box.

Lift the front of the vehicle into the air with the floor jack and place jack stands under the front frame rails. Lower the floor jack until the vehicle securely rests on the jack stands.

Place the drain pan under the right corner of the radiator where the drain cock is located. Turn the radiator drain cock counterclockwise until coolant begins to run from the radiator drain just below the drain cock. Allow all coolant to drain, then tighten the drain cock.

Remove the bolts securing the engine splash shield with the socket and ratchet, and remove the lower splash shield to reveal the alternator and drive belts.

Loosen the belt tensioner pulley lock nut with the socket and ratchet. Loosen the belt adjusting bolt located just above the tensioner with the socket and ratchet until the belt is loose enough to be removed. Remove the alternator and power steering belt from the accessories and crank shaft.

Loosen the alternator adjusting bolt and alternator pivot bolt with the socket and ratchet. Disconnect the plug at the alternator and remove the positive wire from the terminal connector on the alternator. Support the alternator by hand and remove both securing bolts, lower the alternator and set it aside.

Place the drain pan under the thermostat housing. Remove the pressure clamps on the lower radiator and heater hose on the thermostat housing. Remove the lower radiator hose and heater hose from the thermostat housing. Allow any remaining coolant to drain into the drain pan.

Remove the three thermostat housing bolts with the socket and ratchet. Remove the thermostat housing and thermostat.

Install the new thermostat and gasket into the thermostat housing. Position the thermostat so the thermostat bleed valve is pointing straight up (12 o'clock). Install the thermostat housing onto the engine block. Tighten the mounting bolts to 105 inch-pounds with the torque wrench.

Connect the lower radiator hose and heater hose to the thermostat housing. Secure the hoses to the housing with the pressure clamps.

Set the alternator into position and install the mounting bolts. Tighten the alternator mounting bolts to 30 foot-pounds for the 8 mm bolt, 40 foot-pounds for the 10 mm bolt and 40 foot-pounds for the pivot bolt. Install the alternator plug. Connect the battery cable to the terminal connector and tighten the securing nut to 75 inch-pounds with the torque wrench.

Route the belt around the crankshaft, tensioner, power steering pump and alternator. Tighten the adjusting bolt on the belt tensioner until the belt moves no more than one-quarter inch when thumb pressure is applied. Tighten the tensioner pulley locking bolt.

Fill the cooling system with about half the capacity of the coolant that has been removed or new coolant if the fluid is dirty or hasn't been changed in the last two years. Attach the negative battery cable to the battery jumper terminal.

Attach the 4-foot rubber hose section to the bleeder valve located on top of the water inlet in the front of the engine. Route the hose into the drain pan.

Open the coolant bleeder valve with a wrench. Slowly add additional coolant into the pressure cap neck until coolant begins to run from the bleeder valve and into the drain pan. Tighten the bleeder valve and replace the pressure cap.

Start the engine and allow it to reach operating temperature. Any air remaining in the system will evacuate into the pressure reservoir during normal driving.

Install the splash shield and tighten the securing bolts with the socket and ratchet. Lift the vehicle off the jack stands with the floor jack and remove the jack stands. Lower the vehicle to the ground and remove the floor jack.