Changing plastic fitting between bypass hose and intake
 

For the last week or two I've had a slow coolant leak. First I checked the water pump and it seems fine. Following the trail of green sludge, I swung the alternator up out of the way and pressed on the bypass hose where it meets the intake... glug glug glug, coolant came pouring out.

I seem to have the crummy plastic fitting that goes between the hose and the intake. Do I have to drain and refill the cooling system in order to change the fitting? How much coolant is going to come pouring out when I disconnect the hose? Obviously I don't know much about engines but I'm learning... I'd never even removed a belt before today.

Two more questions:

1) Anyone by any chance know the part number for the new metal fitting that replaces the plastic one?

2) Anyone know where I can find a diagram of the 3800 engine? My Haynes manual give step-by-step instructions for how to replace parts, but it doesn't have a good overall diagram of the engine.

Thanks!
Jeremy

Ha, I believe that's the same one that melted on my car many moons ago.

You may have to look at a dealer manual, but try looking at a Chilton's manual first.

fitting part number
 

Don't know if you already got an answer to this with the problems we've been having with the server so here goes.
I did my upper intake gaskets last month and replaced this fitting. The new part is metal and is much more durable
part # 88891743
Good luck
Steve

OregonRuddFan just did this. At my request, he took some pics of it. I'll post them in this thread when I get the chance. You may want to check with him, too.

Thanks, I actually did manage to fix this last week - it took a while but I finally chipped out the old plastic fitting and replace it with the metal one.

Right now I'm working on the metal heater pipe next to it. It's rusted into the intake but hopefully with a little WD-40 it will come out.

Try Coke. No kidding. The acid in Coke will help eat up the corrosion.

heater pipe
 

Yeah, that was a booger to get out. Mine wasn't even corroded. Hopefully your o-ring isn't damaged.

I got the heater pipe out today. It just comes straight out of the lower intake, no threads or O-rings or anything. I soaked it in Wild Cherry Pepsi and then in WD-40 to loosten it, then pried it out. Woo hoo! Now I can go to town on the intake gaskets. Fun stuff...

It's all easy from there. The trick with that coolant pipe is to move the INTAKE, not the pipe, while removing it or installing it.

Keep us posted.