DoDodge Intrepid water outlet box failure

Tiny
TBANISH
  • MEMBER
  • 2002 DODGE INTREPID
  • 6 CYL
  • FWD
  • AUTOMATIC
  • 64,000 MILES
2002 Dodge Intrepid, 6 cyl, A/C, Auto, P/S. The Water Outlet box had a failed seam and blew the top off. I need a diagram to remove and replace it. There is a cable/wire and the intake manifold in the way of accessing the back two bolts.
Here's a link to the part: http://www.autozone.com/autozone/parts/2002-Dodge-Intrepid/Water-Outlet/_/N-jhaltZ9pd7s
You help will be rewarded and much appreciated.
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Monday, November 15th, 2010 AT 8:17 PM

6 Replies

Tiny
FIXITMR
  • MEMBER
The water outlet housing is bolted down with 4 bolts with a 8mm head. 3 bolts can easily be removed with a 1/4 inch 8mm socket and rachet. The 4 bolt is under the intake manifold and can not be easily accessed with a 1/4 inch universal and socket. What you need to borrow/buy is a swivel socket or sometimes referred to as a Flex scocket. This has the universal built into a shallow socket. With this socket the 4th bolt can be easily removed. Tip: Just remember that a 5/16 will also so the trick as it is only 2.5 thou difference in size.
The sockets can be viewed online at:

http://www.skhandtool.com/Default.aspx?fusemode=10&pid=43408
Part #43408
http://www.gearwrench.com/catalog/ratchets_and_sockets/sockets/flex/index.jsp?view=Metric
Part # 80255
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Monday, November 15th, 2010 AT 9:05 PM
Tiny
FIXITMR
  • MEMBER
Disconnect upper radiator hose at outlet connector.
Disconnect the heater hose quick-connect tee from the heater tube at rear of engine.
Disconnect heater tube retaining clip at rear of engine.
Disconnect electrical connector from coolant temperature sensor.
Remove bolts attaching water outlet connector Water Outlet Connector - Removal and Installation To remove outlet connector, move forward until heater tube clears cylinder heads.
INSTALLATION
Clean sealing surfaces. Inspect gasket for tears and cuts. Replace as necessary
Position outlet connector by inserting tube in-between cylinder heads Water Outlet Connector - Removal and Installation
Install attaching bolts and tighten to 12 N m (105 in. Lbs.) Water Outlet Connector - Removal and Installation
Connect retaining clip and heater hose quick-connect tee to the heater tube at rear of engine.
Connect electrical connector to coolant temperature sensor.
Connect upper radiator hose to water outlet connector.
Install upper intake manifold and upper radiator support.
Fill cooling system. Refer to Cooling System Filling in this section
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Monday, November 15th, 2010 AT 9:16 PM
Tiny
TBANISH
  • MEMBER
I can't even see the back right bolt because of the cable in the way. The cable will not remove w/o removing the air intake manifold, and there's a bunch of parts attached to it.
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Monday, November 15th, 2010 AT 9:20 PM
Tiny
FIXITMR
  • MEMBER
The other option is to loosen intake cover and lift so cable/hose can be moved.
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Monday, November 15th, 2010 AT 9:35 PM
Tiny
TBANISH
  • MEMBER
I can't find the bolts that hold down the intake manifold to loosen/remove it. They are well hidden. I've looked all over the manifold. The cable is attached with a clip just behind the water outlet box. It branches off just past and held down with another clip. Tried to force it loose with a screwdriver, no luck. I've searched the web for an answer on how to remove the intake, change the outlet box, or remove this cable w/o success.
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Monday, November 15th, 2010 AT 10:28 PM
Tiny
TBANISH
  • MEMBER
So I'm guessing that I'm not going to get an answer here either. Your instructions of "Remove the Intake" really don't help w/o the advice of where to find the bolts that hold it on. And as much as it's the fault of Dodge engineering to place a part that should be so easy to remove but hide it behind a major engine part, you guys are supposed to be the "experts" to tell me how to remove it. This is strike two for 2carpros, I never got my Mercury question answered to solve that problem either.
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Tuesday, November 16th, 2010 AT 12:35 PM

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