GrandCaravan 2008

Removal & Installation

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3.3L & 3.8L Engines



Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009


CAUTION
Never open, service, or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Avoid physical contact with the coolant. Wear protective clothing and eye protection. Always drain coolant into a sealable container. Clean up spills as soon as possible. Coolant should be reused unless it is contaminated or is several years old.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system down below the thermostat level.
  4.  
  5. Remove the upper radiator hose from the coolant outlet connector (1).
  6.  
  7. Remove the coolant outlet connector bolts (2) and the connector (1).
  8.  
  9. Remove the thermostat (3) from the outlet connector (1).
  10.  
  11. Discard the gasket (4) and clean both gasket sealing surfaces.

    Click image to see an enlarged view

    Fig. Thermostat removal-3.3L and 3.8L engines

  12.  

To install:

  1. To ensure proper seating of the replacement thermostat, carefully remove the bulged metal from the wall of the outlet connector recess that was created during the staking procedure that held the OEM thermostat in place. It is not necessary to re-stake the replacement thermostat into the connector.
  2.  
  3. Position the thermostat to the coolant outlet connector. Align the 2 locating notches (1) on the thermostat (2) to the connector (3). This position will ensure proper location of the thermostat air bleed.
  4.  
  5. Position a new gasket over the thermostat (2) and the connector (3) making sure the thermostat is in the proper position and in the recess provided.
  6.  
  7. Install the thermostat (2) and the connector assembly (3) to the intake manifold. Tighten the bolts to 21 ft. lbs. (28 Nm).

    Click image to see an enlarged view

    Fig. Thermostat position for installation-3.3L and 3.8L engines

  8.  
  9. Install the radiator upper hose to the coolant outlet connector.
  10.  
  11. Fill the cooling system with the proper type and amount of fluid.
  12.  
  13. Run the engine and bleed the air from the coolant system.
  14.  

4.0L Engine



Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009


CAUTION
Never open, service, or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Avoid physical contact with the coolant. Wear protective clothing and eye protection. Always drain coolant into a sealable container. Clean up spills as soon as possible. Coolant should be reused unless it is contaminated or is several years old.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect the upper radiator hose from the thermostat housing (1).
  8.  
  9. Remove the thermostat housing bolts (2).
  10.  
  11. Remove the housing, thermostat, and gasket.

    Click image to see an enlarged view

    Fig. Thermostat removal-4.0L engine

  12.  

To install:

  1. Clean the gasket sealing surfaces.
  2.  
  3. Install thermostat and the gasket into the thermostat housing. For ease of installation, install the bolts in the housing for thermostat and gasket retention.
  4.  
  5. Install the thermostat and housing (1) to the intake manifold. Tighten the bolts (2) to 105 inch lbs. (12 Nm).
  6.  
  7. Connect the radiator hoses and install the hose clamp.
  8.  
  9. Fill the cooling system with the proper type and amount of fluid.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Run the engine and bleed the air from the coolant system.
  14.  

 
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