300, 300C & Magnum 2006-2008, Charger 2006-2008

Removal & Installation

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2.7L Engine



  1. Disconnect the negative battery cable.
    CAUTION
    Do not remove pressure cap with the system hot and under pressure because serious burns from coolant can occur.

  2.  
  3. Drain the cooling system into a suitable container
  4.  
  5. Disconnect the radiator lower hose from thermostat housing.
  6.  
  7. Remove nuts from the heater tube flange studs.

    Click image to see an enlarged view

    Fig. Thermostat housing (1), bolt (2), nuts (3) and weeping hole (4)-2.7L engine

  8.  
  9. Loosen the starter bolt at heater tube bracket.
  10.  
  11. Pull the heater tube out of thermostat housing and position out of the way.
  12.  
  13. Remove thermostat housing (1), O-ring (2) and thermostat (4).
  14.  
  15. Remove thermostat housing bolts (3).
  16.  

To install:

  1. Thoroughly clean the gasket sealing surfaces.
    NOTE
    Install thermostat with the bleed valve located at the 12 o'clock position, between tabs on seal.

  2.  
  3. Install thermostat and seal (2) into thermostat housing (1).
  4.  
  5. If removed, install the two studs.
  6.  
  7. Lubricate a new heater return tube O-ring with coolant.
  8.  
  9. Position the heater return tube flange over the two studs. Install the 3 retaining nuts and torque to 53 inch lbs. (6 Nm).
  10.  
  11. Tighten the starter bolt to 40 ft. lbs. (54 Nm).
  12.  
  13. Connect the lower radiator hose to thermostat housing. Install the hose clamps.
  14.  
  15. Refill cooling system
  16.  
  17. Connect the negative battery cable. Start and warm the engine. Check for leaks.
  18.  

3.5L Engine



  1. Disconnect the negative battery cable.
    WARNING
    Do not remove pressure cap with the system hot and under pressure because serious burns from coolant can occur.

  2.  
  3. Drain the cooling system.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Detach the electrical connectors from the engine oil and power steering pressure switches.
  8.  
  9. Disconnect the radiator and heater hoses from thermostat housing.
  10.  
  11. Remove thermostat housing bolts.
  12.  
  13. Remove the housing, thermostat, and gasket.
    NOTE
    The OEM thermostat is staked in place at the factory. To ensure proper seating of the replacement thermostat, carefully remove the bulged metal from thermostat housing using a suitable hand held grinder. It is not necessary to re-stake the replacement thermostat into thermostat housing.



    Click image to see an enlarged view

    Fig. Thermostat housing/coolant inlet (1), thermostat (2) and gasket (3)-3.5L engine

  14.  

To install:

  1. Thoroughly clean the gasket mating surfaces.
  2.  
  3. Position a new gasket on thermostat and housing.
  4.  
  5. Install thermostat housing, gasket and mounting bolts onto block. Tighten attaching bolts to 105 inch lbs. (12 Nm).
  6.  
  7. Install the radiator hose.
  8.  
  9. Install the bypass hose.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Fill the cooling system. Start and warm the engine. Check for leaks.
  14.  

5.7L Engines



  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the radiator hose from thermostat housing.
    NOTE
    Thermostat o-ring is part of thermostat and is not serviced separately.

  6.  
  7. Remove thermostat housing mounting bolts, thermostat housing and thermostat.

    Click image to see an enlarged view

    Fig. Thermostat housing (1), thermostat (2) and retaining bolt (3)-5.7L engine

  8.  

To install:

  1. Clean the mating areas of timing chain cover and thermostat housing (1).
    NOTE
    Install thermostat with the bleed valve located at the 12 o'clock position.

  2.  
  3. Install thermostat (spring side down) into recessed machined groove on timing chain cover with bleed valve located at the 12 o'clock position.
  4.  
  5. Position thermostat housing on timing chain cover.
  6.  
  7. Install the two housing-to-timing chain cover bolts (3). Tighten bolts to 112 inch lbs. (13 Nm).
    WARNING
    Thermostat housing must be tightened evenly and thermostat must be centered into recessed groove in timing chain cover. If not, it may result in a cracked thermostat housing, damaged timing chain cover threads or coolant leaks.

  8.  
  9. Attach the lower radiator hose to thermostat housing.
  10.  
  11. Carefully lower the vehicle.
  12.  
  13. Fill the cooling system.
  14.  
  15. Connect the negative battery cable. Start and warm the engine. Check for leaks.
  16.  

 
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