Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2004 Chrysler Intrepid (CANADA) V6-2.7LFACTORY OEM SERVICE PROCEDURE
Coolant: Service and Repair
COOLANT OUTLET CONNECTOR 2.7L
REMOVAL
WARNING: DO NOT REMOVE PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.
1. Drain cooling system.
2. Remove upper intake manifold.
3. Remove screws attaching heater tube to outlet connector.
4. Disengage tube from outlet connector only enough for connector removal.
5. Remove bolts attaching water outlet connector.
6. Remove outlet connector.
INSTALLATION
1. Clean sealing surfaces. Inspect gaskets for tears and cuts. Replace as necessary.
2. Install outlet connector and tighten bolts to 12 Nm (105 in. lbs.) .
3. Inspect and replace heater supply tube O-ring as necessary.
4. Lubricate O-ring and insert heater tube assembly into outlet connector. Tighten screws to 3 Nm (30 in. lbs.).
5. Install upper intake manifold.
6. Fill cooling system.
REMOVAL
WARNING: DO NOT REMOVE PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.
1. Drain cooling system.
2. Remove upper intake manifold.
3. Remove screws attaching heater tube to outlet connector.
4. Disengage tube from outlet connector only enough for connector removal.
5. Remove bolts attaching water outlet connector.
6. Remove outlet connector.
INSTALLATION
1. Clean sealing surfaces. Inspect gaskets for tears and cuts. Replace as necessary.
2. Install outlet connector and tighten bolts to 12 Nm (105 in. lbs.) .
3. Inspect and replace heater supply tube O-ring as necessary.
4. Lubricate O-ring and insert heater tube assembly into outlet connector. Tighten screws to 3 Nm (30 in. lbs.).
5. Install upper intake manifold.
6. Fill cooling system.
Factory Service Tools
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
Disclosure: Verified tool recommendations may earn an affiliate commission at no cost to you.
When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.