From:jb5148m, I spent 4 days removing the tubling lines, was doing the job for my son-in law, he had another car, therefore, there was no hurry. Below is how I did the job, it came out OK, Van been running good for over six weeks.
Mechanic at the Chrysler Dealership said they removed the windshield wiper arms, complete linkage, motor assembly,
it all comes out as a complete unit, remove about 6 bolts, 4 nuts, one plug, one hose, easy removable. Gives you a lot more room, still could not get the heater supply and return tubing line out, (steel line not a hose), used a sawall, cut the steel tubing line. I'm in the process of replacing chrysler part number 4677557AA, heater supply and return tubling line for rear heater on 3.8 litre engine. Chrysler cost: $366.00, I shopped the web, found an aftermarket, from rockauto, dorman, p/n: 626300, price $70.79. The different is Chrysler upgraded their part from steel to aluminum tubling. The aftermarker is as original made of steel. Therefore, it does not bend, this is why you can not easily remove or replaced the part. With the complete wiper assembly removed, I still could not fit the part in, I, removed the intake manifold. Again, it was not difficult, 2 bolts, 2 nuts, 2 nuts on back side of intake, disconnect EGR pipe, some plugs, and hoses. More time consuming than work.
Will need to purchase a new intake manifold gasket, and EGR gasket. They will likely try to sell you an intake manifold gasket kit for $19.99, you only need one gasket out of this kit. I had to go to three auto part stores. At Advance Auto, purchase Fel-Pro MS 94566, 48163, intake manifold upper set Chrysler V-6 3.8L, this set include the EGR gasket, set cost $2.99. Once, I got the intake manifold off, the rear heater supply & return tubing line went in smoothly. I'm sending you this info, so as, you can pass it along to anyone else who has this problem.
Monday, July 11th, 2011 AT 9:23 PM