Service Procedure

Coolant Temperature Sensor Replacement

1. Partially drain coolant from radiator (below thermostat housing level). Save coolant.

FIGURE 1:

2. Detach wiring connector from coolant temperature sensor. (See Figure 1.)

NOTE: For removal, grasp the connector body and pull off as straight as possible, avoiding excessive wiggling of the wiring and connector.
Service Procedure (continued)

Coolant Temperature Sensor Replacement (continued)

3. Remove the coolant temperature sensor from engine.

4. Apply an even coat of sealant to the threads of the replacement sensor. (Use MOPAR Perfect Seal Sealing Compound, Part No. 4-41 or 3419115, or equivalent.)

5. Install the new sensor and torque to 25 foot-pounds.

Note: To prevent damage to sensor, do not use impact tools to install.

6. Replace engine coolant.

FIGURE 2:

Coolant Temperature Sensor Wiring Connector Replacement

Note: A few of the involved vehicles may already have the new connector installed. It can be identified by the heavier (12 gage) leads and the in-line quick-disconnect in one lead. (See Figure 2.) Omit the following steps for those vehicles.

1. Disconnect battery.

2. Peel back tape on harness to expose approximately 8 inches of the coolant temperature sensor wiring. (Refer to Figure 2.)

3. Cut off the existing sensor connector and wiring, leaving sufficient wiring length for ease of splicing to the replacement connector.

4. Splice the replacement connector leads to the harness wires by removing one inch of insulation from the ends and twisting them together. Heat each splice, using a high temperature soldering gun; apply rosin-type solder until it flows freely. Do not use acid core solder. Wrap each spliced wire with a minimum of three layers of suitable electrical tape.

5. Tape the new wiring into the harness. Fold and tape back the excess length of the longer connector lead, leaving the in-line quick-disconnect exposed. See Figure 2.

6. Attach the connector to the new coolant temperature sensor.

7. Reconnect battery.