Dodge ram truck 3500 1996 Service Manual page 332

7 - 48 COOLING SYSTEM
R E M O V A L AN© INSTALLATION (Continued)
Fig. 74 Support Rod—8.0L ¥-10 Engine
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 (NUMBER
6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20)
MAY BE USED FOR LARGER CLAMPS. ALWAYS
WEAR SAFETY GLASSES WHEN SERVICING CON­
STANT TENSION CLAMPS.
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.
(4) Remove upper radiator hose clamp. Remove
upper radiator hose at thermostat housing.
(5) Disconnect the wiring connectors at both of the
sensors located on thermostat housing.
(6) Remove six thermostat housing mounting bolts,
thermostat housing, gasket and thermostat. Discard
old gasket.
INSTALLATION.
(1) Clean mating areas of intake manifold and
thermostat housing.
(2) Check the condition (for tears or cracks) of the
rubber thermostat seal located in the intake manifold
(Fig. 73) (Fig. 75). The thermostat should fit snugly
into the rubber seal.
(3) I f seal replacement is necessary, coat the outer
(metal) portion of the seal with Mopar® Gasket
Maker. Install the seal into the manifold using Spe­
cial Seal Tool number C-3995-A with handle tool
number C-4171.
(4) Install thermostat into recessed machined
groove on intake manifold (Fig. 75).
(5) Install gasket on intake manifold and over
thermostat (Fig. 75).
TEMP. C O O L A N T
RUBBER LIP SEAL J9407-16
Fig. 75 Thermostat—8. OL ¥-10 Engine
(6) Install housing-to-intake manifold bolts.
Tighten bolts to 25 N-m (220 in. lbs.) torque.
CAUTION: Housing bolts should be tightened
evenly to prevent damage to housing and to pre­
vent leaks.
(7) Connect the wiring to both sensors.
(8) Install the upper radiator hose and hose clamp
to thermostat housing.
(9) Install support rod.
(10) Fill cooling system. Refer to Refilling Cooling
System i n this group.
(11) Connect negative battery cable to battery.
(12) Start and warm engine. Check for leaks.
THERMOSTAT—DIESEL ENGINE
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES­
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
Do not waste reusable coolant. I f the solution is
clean, drain the coolant into a clean container for
reuse.