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How to Replace the Thermostat in a 94 Dodge Caravan

Over time, the mechanical spring inside of the thermostat weakens. The giggle valve clogs up and restricts the passage of steam though the thermostat, and eventually, your 1994 Dodge Caravan stops producing heat inside of the vehicle. The thermostat is designed to fail in the open or "safe" position, thus preventing the Caravan from overheating. This protects the engine from damage, but thermostat replacement is important because the vehicle will not reach the correct operating temperature.

Instructions

1

Remove the radiator cap from the radiator. The cap is on the left side, on the top of the radiator. This releases pressure in the coolant system. Do not remove the cap while the engine is hot.

2

Remove the band clamp that secures the lower radiator hose to the radiator outlet. Use a screwdriver to remove the clamp. Pull the hose off the radiator and drain the fluid into a drainage pan. Slide the hose back onto the radiator outlet and secure it in place with the band clamp.

3

Follow the upper radiator hose to the point where the hose connects to the top of the engine. Remove the band clamp from the hose with the screwdriver and pull the hose off the thermostat housing. Push the hose off to the side to gain access to the housing.

4

Remove the two bolts that secure the thermostat housing to the manifold of the Dodge Caravan with a 9/16-inch socket and ratchet. Lift the housing off the Caravan to expose the thermostat.

5

Pull the old thermostat out of the intake and discard it.

6

Shove a rag into the hole the thermostat sat in to prevent old gasket material from falling into the cooling system.

7

Scrape the old thermostat gasket off the intake manifold and the bottom of the thermostat housing and wipe everything down with a rag.

8

Remove the rag and place the new thermostat into the Caravans intake. The end with the spring on it sits inside of the intake.

9

Place a bead of RTV silicone around the base of the thermostat housing and place the housing back onto the intake. Secure it with the bolts.

10

Reconnect the upper radiator hose and secure it with the band clamp.

11

Drain the radiator fluid back into the radiator, using the filler cap. Replace the radiator cap once finished.

Posted by Unknown at 8:30 AM

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