'02 Intrepid / 2.7 Water outlet leaking, top plate seam, fairly common. Bought replacement part which includes long pipe. Read and was told that the upper intake plenum has to come off. Ok, removed it and find that after you take the water outlet housing off, you need to also replace the long tube that connects it to the back of the engine. The problem is that there appears to be no way to remove this original pipe and since you now HAVE to install the new pipe (because it has the bleeder valve now, instead of being on the housing top plate) you can't just put in the new housing. Has anyone out there replaced the water outlet and if so, did you run into a problem with the long connecting pipe / how did you get it out? Although it's loose after being disconnected, it won't come out because it's under the lower intake and even the cylinder heads seem to be in the way. Would appreciate any help with this. Can't believe you'd have to tear half the engine down to replace a water outlet housing.

 

Unbolt the plenum and lift it up and put something under it to hold it up (you need about 1 inch). In the rear of the engine take off the hose then there is a bracket that holds the tube, take it off. Then you can pull the tube out. You have to wiggle and twist it some but it will come out. Its a pain but it will come out. You might have to put a jack under the front of the engine to get it up some for clearance over the rad support.