2.7L Thermostat and Heater Supply Hose Modification (Revised)

The 2.7L thermostat modification applies to engines with build codes prior to 04/20/98 (the engine build date is located on a label attached to the left rear valve cover). In-plant modified thermostats may have a white paint dot on the thermostat housing. All 2.7L engines must have the heater hose modification performed.


1. Follow the procedures listed in the 1998 Concorde/Intrepid service manual publication number 81-270-8140 to remove the thermostat on 2.7L engine applications.

WARNING:
DO NOT REMOVE THE PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM HOT COOLANT CAN OCCUR.





2. Press down on the secondary poppet spring. Remove and discard the secondary poppet c-clip, and spring (Figure 4).

3. Reinstall the thermostat into the engine following service manual procedures.





NOTE:
THE THERMOSTAT AIR BLEED MUST BE AT THE 12:000-CLOCK POSITION (FIGURE 5).





4. Identify the heater supply hose (Figure 6).

NOTE:
THE VEHICLE MAY HAVE ONE OF TWO CONFIGURATIONS. CONFIGURATION WILL DETERMINE PARTS REQUIREMENT.

5. If the heater supply hose is configured as shown in Figure 6 "A", obtain p/n's heater supply hose 04596346AA, heater supply hose 04767170AB, four hose clamps 06502018 and two hose clamps 04592126. If the heater supply hose is configured as shown in Figure 6 "B", obtain p/n's heater supply hose 04767170AB, four hose clamps 06502018 and two hose clamps 04592126.

6. For configuration "A", remove and discard the existing heater supply hose.

7. For configuration "A", remove the quick connector from heater supply hose p/n 04596346AA and install it onto the heater supply tube coming out of the back of the engine.

NOTE:
ORIENT THE QUICK CONNECT SO THE HOLES FACE UP/DOWN AND THE FLATS FACE LEFT/RIGHT.

8. For configuration "B", leave the quick connect attached to the heater supply tube and remove and discard the rest of the supply hose assembly.





9. For both configurations, cut the new hose p/n 04767170AB as shown in Figure 7.

10. For both configurations, insert the Tee into the cut section of the heater hose. Use two hose clamps p/n 06502018 to complete the assembly. Before tightening the clamps, orient the Tee to the 2:00 0-Clock position as viewed from the front of the vehicle (Figure 7).

11. Install one end of the 3/8 inch hose onto the Tee using hose clamp p/n 04592126.

12. Install the heater hose onto the heater supply tube and heater core. Use clamps p/n 06502018 to secure both ends.





13. Install the remaining end of the 3/8 inch hose to the coolant pressure bottle. Use clamp p/n 04592126. The final heater hose configuration is shown in Figure 8.

14. Use Mopar long lite coolant p/n 0501 1764AB and follow all cooling system fill procedures listed in the service manual. It will take approximately 8.5 L (9 quarts) to refill the system.

NOTE:
COOLING SYSTEM FILL PROCEDURES ARE CRITICAL TO OVERALL COOLING SYSTEM PERFORMANCE.

15. Operate the engine at 2000 to 2300 RPM for 20 minutes. This will remove any remaining air from the cooling system. The DRB Ill� can be used to set the engine RPM within engine actuators, RPM set. Periodic monitoring of this procedure is necessary since the actuator test will time out in 5 minutes. The reset feature can be used to continue the engine RPM actuator feature.

NOTE:
DO NOT EXCEED 2500 RPM DURING THE AIR PURGE PROCEDURE.