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Discussion Starter #1
Greetings,

Yesterday I undertook to pull and replace the radiator and thermostat on my 2004 Intrepid 2.7L, going off the Chilton repair manual. According to the manual, to fully drain the system I need to remove/release the engine coolant block plugs, however, I was unable to locate them based on the picture in the manual. In searching the forum here today, somebody stated the owners manual says they're under the exhaust manifold, though I haven't had a chance to look again after arming myself with that information.

Other have posted that they're not worth finding, but I've already spent about a half an hour underneath the engine looking for them, and I'm both curious and stubborn. Any help would be greatly appreciated.

-IntMinn
 

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Daytrepper,

Thanks, with the photo I was able to spot them, they were higher up than I was expecting. I couldn't get a line of sight on them from directly beneath, I had to look from over by the wheel to get a clear line of sight. I'm going to throw ten minutes at getting them off/loose, and then move on. I appreciate the help,

-IntMinn
 

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If you find it difficult to R&R the plugs, you could do just as well for flushing the block by connecting a water hose (adapt to heater or radiator hoses using iron pipe fittings) from your house system. To be safe, put an adjustable pressure regulator set to 18 psi in line with the hose, especially if the radiator and heater core are still connected.

With thermostat removed, flush all circuits and components (water pump, block, reservoir, and heater core) with full flow for 3 or 4 minutes in both directions for best effect.

When done, pour 3 or 4 gallons of distilled water ($1 a gallon at grocery store) thru everything (again, in both directions) to displace 90+% of the tap water with distilled, then drain out what you can from radiator and block with lower radiator hose disconnected, install thermostat (after testing for proper opening and closing in pan of water on stove with thermometer), add 1/2 system capacity (9.4/2 = 4.7 qts.) of 100% G05 antifreeze in your brand of choice (Zerex G05 - yellow, Chrysler/Mopar 5 Year/100kMile 68048953AB MS-9769 - reddish, or Ford/Motorcraft VC-7-B - yellow), and top off remaining space with distilled water using FSM fill and bleed procedure.
 

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Discussion Starter #5
Peva,

Thanks for the recommendation, but living in Minnesota, a home coolant flush is not in the cards (we've been running a daytime high of -4 F here the last few days). I recently heard that Boy Scouts add a tiny amount of bleach (tiny enough that it's still potable) to their drinking water to keep it from freezing, and I considered flushing with some gallons of said bleach water, but I'm not in the mood to clean 5-10 gallons off the garage floor, or ensure that it all drains into containers.

I'm knee deep in swapping out the radiator and thermostat/housing (the radiator is out and just pulled the bolts from the thermostat housing, but just need to pull the hoses from it), and when I'm finished, assuming that the car runs, I'll likely take it to a shop for a final leak test, and then a flush.

Cheers,
-IntMinn
 
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