300M, Concorde, Intrepid, LHS, 1998-2004

Removal & Installation

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2.7L Engine



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

  2.  
  3. Drain cooling system.
  4.  
  5. Remove radiator lower hose from thermostat housing.
  6.  
  7. Remove nuts from heater tube flange studs.
  8.  
  9. Loosen starter bolt at heater tube bracket.
  10.  
  11. Pull heater tube out of thermostat housing and position out of the way.
  12.  
  13. Remove bolt and two studs.
  14.  
  15. Remove thermostat housing, O-ring and thermostat.
  16.  
  17. Remove thermostat housing bolts.
  18.  

To install:

  1. Clean 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 into thermostat housing .
  4.  
  5. If removed, install two studs.
  6.  
  7. Install thermostat, thermostat housing and O-ring and bolt. Tighten attaching bolts to 105 inch lbs.(12 Nm).
  8.  
  9. Lubricate new heater return tube O-ring with coolant.
  10.  
  11. Position heater return tube flange over two studs. Install nuts.
  12.  
  13. Tighten retaining nuts to 53 inch lbs.(6 Nm).
  14.  
  15. Tighten starter bolt to 40 ft. lbs. (54.3 Nm).
  16.  
  17. Connect the lower radiator hose to the thermostat housing. Install hose clamps.
  18.  
  19. Refill cooling system.
  20.  
  21. Inspect for leaks.
  22.  
  23. Connect negative cable.
  24.  

3.2L & 3.5L Engines



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

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

  14.  

To install:

  1. Position gasket on thermostat and housing.
  2.  
  3. Install thermostat housing, gasket and mounting bolts onto block. Tighten attaching bolts to 105 inch lbs. (12 Nm).
  4.  
  5. Install radiator hose.
  6.  
  7. Install bypass hose.
  8.  
  9. Connect electrical connectors from engine oil and power steering pressure switches.
  10.  
  11. Connect negative cable.
  12.  
  13. Fill cooling system.
  14.  
  15. Inspect for leaks.
  16.  
  17. Lower vehicle on hoist.
  18.  

 
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