How to Change the Thermostat in a Plymouth Neon

The front-wheel drive Neon was intorduced as a sedan and a coupe by both Dodge and Plymouth. The following steps guide you through the installation of a new thermostat in the 1996 to 1999 Neon. Changing the thermostat in a Plymouth Neon is a beginner do-it-yourself project for most vehicle owners.

Difficulty: Challenging

Instructions

Things You'll Need:

• Mechanic's toolset, including a full socket set, wrenches and screwdrivers
• Replacement thermostat, new or rebuilt
• New gasket for thermostat

1. Make sure the engine is completely cool. Disconnect the negative battery cable. Drain the cooling system until the level is below that of the thermostat.

2. Disconnect the coolant recovery system hose from the thermostat housing. Unfasten the upper radiator hose clamp. Slide the hose off the fitting.

3. Remove the bolts for the thermostat-engine outlet housing connector. Lift off the housing. Take the thermostat off the engine. Take off the O-ring and clean the sealing surfaces well.

4. Set the new the thermostat onto the thermostat housing/outlet connector. Align the vent carefully with the notch in the cylinder head.

5. Install the thermostat housing/outlet connector to the cylinder head. Put the retaining bolts in position. Tighten the bolts to 9.2 foot pounds. Reattach the upper radiator hose. Secure the hose with the clamp.

6. Connect the hose for the coolant recovery system. Fill the cooling system with the appropriate type and amount of coolant. Reconnect the battery cable.

7. Start the engine. Allow it to warm up to operating temperatures. Check the coolant level and add coolant as necessary.

Tips & Warnings

• The hoses slide onto fittings or connectors that grip the individual hose and hold it in place with a clamp. No special tools are required to remove or reconnect hoses. Label the hose and its connectors before separating.
• Drain the coolant into a container that can be sealed. Dogs and cats will drink coolant left in open containers or on the floor and ingestion is usually fatal. Reuse coolant unless it is contaminated or several years old. Dispose of coolant properly.

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