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'* 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'* manual first.

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'* 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.

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'* 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.