Coolant bypass repair

Repair / Installation tips:

Special tools needed? Have to remove other parts to reach this one? Any left-hand threads, sharp edges, messy fluids or other pitfalls to avoid?

You must partially remove the intake plenum in order to get to one of the four fasteners 8mm, securing the flange. This is senseless engineering blunder that adds to the otherwise simple 20 minute replacement, the added time anf frustration, potential damage to the intake plenum gasket, and the potential for a call back issue it the plenum does not get sealed.

This job had to be redone because the new flange did not seal, and the new flange did not have an effective glue joint between the plastic housing parts, manufacturing defect. The housing leaked at the bond seam. It also leaked around the base and out of the bolt holes.

Once the damaged part was removed it was observed that the aluminum mating surface had small voids in the casting and poor machining creating the potential sealing issues at the o-ring. I filled voids in the bottom of the flange with permatex in order to make a seal possible.

This is very important - if you look inside the new housing, locate the glue seam located at the step in the housing, this is a leaker potential. With the housing absolutly clean and absolutly dry, use a q-tip and run a thin bead of permatex over the glue joint from the inside of the housing, this will prevent a leak due to manufacturing defects. Water pressure will not overcome the silicone if the bead is on the inside. Let the bead dry completely before assembling.

Another design flaw - The nipples are plastic, the hose clamps are broad and you will need a pair of thin pliers to get to the hose clamps. If you use the wrong pliers, you may apply undo force to the plastic hose nipples and potentially break the housing at the aformentioned housing seam. The uppermost nipple is delicate and care is needed when removing the upper small hose.

Add permatex around the shank of each bolt to ensure you get a seal in the bolt holes, the design of the flange allows the potential for coolant to bypass the o-rings and exit through the bolt holes.

Read more: http://wiki.answers.com/Q/How_do_you_install_water_outlet_for_2001_Dodge_Intrepid_2.7#ixzz15xL8OEH6