Dodge Ram Truck 1500-2500-3500. Manual — part 240
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUM-
BER 6094).
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment
clamp with a matching number or letter.
3. Remove radiator hose clamp and hose from ther-
mostat housing (1).
4. Remove the three water outlet-to-cylinder head
bolts and remove the water outlet connector.
5. Clean the mating surfaces of the water outlet con-
nector and clean the thermostat seat groove at the
top of the thermostat housing.
8.3L ENGINE
1. Partially drain the cooling system below the ther-
mostat level.
2. Disconnect throttle body air inlet hose, remove air
cleaner housing assembly.
3. Disconnect upper radiator hose from thermostat
housing.
4. Remove thermostat housing attaching bolts in the
reverse order of the torque sequence.
5. Remove thermostat housing.
6. Remove thermostat from housing and discard ther-
mostat housing gasket.
7 - 66
ENGINE
DR/DH
INSTALLATION
3.7L/4.7L ENGINE
1. Clean the mating areas of the timing chain cover
and the thermostat housing.
2. Install the thermostat (spring side down) into the
recessed machined groove on the timing chain
cover.
3. Position the thermostat housing on the timing chain
cover.
4. Install the housing-to-timing chain cover bolts.
Tighten the bolts to 13 N·m (112 in. lbs.).
CAUTION: The housing must be tightened evenly
and the thermostat must be centered into the
recessed groove in the timimg chain cover. If not,
it may result in a cracked housing, damaged tim-
ing chain cover threads or coolant leaks.
5. Install the lower radiator hose on the thermostat
housing.
6. Install the splash shield.
7. Lower the vehicle.
8. Fill the cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
9. Connect negative battery cable.
10. Start and warm the engine. Check for leaks.
5.7L ENGINE
1. Position the thermostat and housing (2) on the
front cover.
2. Install thermostat housing bolts (1). Tighten the
bolts (1) to 13 N·m (112 in. lbs.).
3. Install the radiator hose (4) onto the thermostat
housing (2).
4. Fill the cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
5. Connect negative battery cable.
6. Start and warm the engine. Check for leaks.
DR/DH
ENGINE
7 - 67
5.9L DIESEL ENGINE
1. Inspect thermostat seal for cuts or nicks. Replace if
damaged.
2. Install the thermostat into the groove in the top of
the cylinder head (2).
3. Install the thermostat housing (1) and bolts. Tighten
the bolts to 10 N·m (89 in. lbs.) torque.
4. Install the radiator upper hose and clamp.
5. Fill the cooling system with coolant (Refer to 7 -
COOLING - STANDARD PROCEDURE).
6. Connect the battery negative cables.
7. Start the engine and check for coolant leaks. Run
engine to check for proper thermostat operation.
8.3L ENGINE
CAUTION: Do not use a metal scraper to clean alu-
minum sealing surfaces, as damage to surfaces
may occur. Use only a plastic scraper and Mopar
T
Brake Parts Cleaner or the equivalent
1. Clean both sealing surfaces using a plastic scraper
and Mopar
T
Brake Parts Cleaner or the equivalent.
Take care not to scratch or gouge sealing surfaces.
2. Install new thermostat into thermostat housing.
3. Install new thermostat housing gasket.
7 - 68
ENGINE
DR/DH
4. Install thermostat housing to chain case cover.
5. Tighten thermostat housing bolts in the sequence
shown in to 11 N·m (95 in. lbs.).
6. Connect upper radiator hose to thermostat housing.
7. Install air cleaner housing assembly, connect throt-
tle body air inlet hose.
8. Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
FAN DRIVE VISCOUS
DESCRIPTION
GAS ENGINES
The thermal viscous fan drive is a silicone-fluid- filled
coupling used to connect the fan blades to the water
pump shaft. The coupling allows the fan to be driven
in a normal manner. This is done at low engine
speeds while limiting the top speed of the fan to a pre-
determined maximum level at higher engine speeds.
DR/DH
ENGINE
7 - 69
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