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Home >> Dodge and Ram >> 2003 >> Durango Base, 5.9 Z, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 38 (Engine Cooling - Removal & Installation) >> Engine Coolant Thermostat >> Diagnosis And Testing-Thermostat >> Installation-3.9L/5.9L Engines

Installation-3.9L/5.9L Engines

WARNING: This page is about a different car, the 2003 Dodge Dakota. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean mating areas of intake manifold and thermostat housing.
  2. Install thermostat (spring side down) into recessed machined groove on intake manifold.
  3. Position thermostat housing to intake manifold. Note the word FRONT stamped on housing (Fig 1). For adequate clearance, this must  be placed towards front of vehicle. The housing is slightly angled forward after installation to intake manifold.
    Fig 1: Thermostat Position - 5.9L Engines
    G02656462Courtesy of DAIMLERCHRYSLER CORP.
  4. Install two housing-to-intake manifold bolts. Tighten bolts to 23 N.m (200 in. lbs.) torque.
  5. Install radiator upper hose to thermostat housing.
    CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to (Fig 2) for correct 3.9L and 5.9L engine belt routing. The correct belt with correct length must be used.
    Fig 2: Belt Routing - 5.9L Engines
    G02656463Courtesy of DAIMLERCHRYSLER CORP.
  6. Air Conditioned vehicles; Install generator. Tighten bolts to 41 N.m (30 ft. lbs.).
  7. Install support bracket (generator mounting bracket-to-intake manifold). Tighten bolts to 54 N.m (40 ft. lbs.) torque.
  8. Install accessory drive belt (Fig 2)(Refer to DRIVE BELTS ).
  9. Fill cooling system (Refer to STANDARD PROCEDURE ).
  10. Connect battery negative cable.
  11. Start and warm the engine. Check for leaks.
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