If anyone'* interested, the following info may be helpful if your Bonnie has the plastic coolant bypass fitting and it breaks off, as mine recently did on my '92 SSE */c at 165,000 miles.

Here'* what happened. I noticed some coolant on the top of the intake near the bypass hose, so I assumed that the hose was leaking, although there was no sign of coolant running along the bottom of the hose or dripping at the end. I loosened the hose clamps and when I gently turned the hose to try to remove it, the bypass fitting snapped into two pieces so that half of it was in the end of the hose, and the other half was still in the intake.

I found an easy way to remove the broken piece of the fitting from the intake. I gently tapped a nipple removal tool (a $3 tool used to disassemble PVC sprinkler pipes) into the opening on the broken part of the fitting and slowly turned it counterclockwise. It removed the broken piece of the fitting quickly and easily, and it only took 1 attempt to be successful. I bought a replacement fitting (metal) from Pep Boys for $6...shame on GM for making the part out of plastic.

Sounds familiar. Just happened to me two months ago. What I did was use a hacksaw blade and sawed in 3 places and removed the broken pieces by hand. You have to be careful not to 1) saw into the metal housing and 2) drop any plastic pieces inside. It turned out very well.

Unfortunately, I paid $25 Cdn for the metal fitting and $22 for the bypass hose from the dealer. (my brother subsequently told me that you can get that fitting at Home Depot for $1 - I never checked.... :? )

Congratulations, you got lucky. I tried the same tool a year ago when the fitting on my 92 SE broke and it did not work at all. After numerous tries with that and other tools, I ended up using a hacksaw to cut the piece like faisalmali did and then a screwdriver and hammer to chip out the parts.

This weekend'* project involves replacing the failed lower intake gaskets and the throttle body gasket. Since there is no coolant in the car anyway, I figured it was a good time to put in a 180 degree thermostat also.

I removed this plastic fitting from my lower intake - It'* not broke, but I want to put in a fresh one. This thread speaks of one from Home Depot? I'm guessing you're talking about an NPTmale - to - barb standard plastic pipe fitting that I might use on my well pump at home. I'm skeptical on that, with head and antifreeze vs. domestic cold water.
Also, it looks like my fitting had an o-ring on it and straight threads? Can someone verify and / or give me part numbers and / or a source for this nipple and o-ring? Thanks. Mike

Wow.. this post is OLD that you brought up.

Start a new post, so we can help you, I know of the part you are talking about.

Just did this, along with a LIM job on my 96 sle. My bypass elbow was not threaded, but it did break off about flush with the fitting so that about 1/2 and inch of plastic was still in my tensioner assembly and in the LIM. I dug it, and the gooey excuse for an O-ring out, and gently cleaned the gasket maker out of the holes. Looks like this leaked before i got the car and instead of fixing the problem correctly, previous owner decided RTV would fix everything. It did,...for a while i guess.

Luchboxx, totally different application and part. Not even close.

Troyport, please check the dates on super-old topics before replying. We've been suggesting this for years as preventive maintenance. Steel replacements are available all over. In fact, I doubt you can find plastic any longer.