Hello.

I am replacing a bad Coolant Bypass Hose on my 1990 Honda Accord 2.2.

After I loosened both the clamps and removed the thermostat side, the intake side came out with the nipple/barb intact. [referred to as just "nipple" going forward]

I have included a diagram that includes a picture of the nipple that came out still stuck to the hose.



I have a few questions and would really appreciate some help, because I don't have a clue where to go from here. I am really hoping for something quick and easy.

Is this nipple a press-in? Or is there some of the nipple missing / still in the manifold?

Is there a way to put in a new one? If so, where would I get one? I have been searching all day for one and can't seem to find anything remotely similar.

Is there any way to get around tapping the manifold?

Can I go down to the junkyard and pull a nipple from another Accord?

The nipple looks the same size as the nipple on the thermostat housing. Can I find [the much cheaper] thermostat housing and remove the nipple from it and replace it in the manifold spot?

Thank you very much. I really appreciate the help.

esmzoso

 

From everything i've seen it looks like that nipple is actually machined on. The nipple looks simular to the kind on a heater core and when those break you need a new heater core. Was the bypass hose leaking on the car? I'll look a little more and see what I can find.

 

IS what I have circled the nipple that broke off because if it is it doesn't look good.

 

Hello.

Yeah, I think it's the same nipple.

Basically, it's the bypass from the thermostat housing to the intake manifold.

In reference to the other reply: yes, the hose was leaking. Actually, it looks as if the nipple may have been leaking also.

I was getting a steady stream of coolant under the car. Upon further investigation, I discovered that the hose was leaking. The nipple came out still attached to the hose.

If I can't get a replacement, I'm going to the junkyard and get a thermostat housing and pull the nipple from that and put it in the intake manifold. I'll have to find something to hold it in place; JB Weld, RTV, something.

I don't want to pull the top of the motor off the car right now. It's too stinking cold here.

_________

A little background:

I bought the car for $350.00. I have basically been replacing the entire coolant system as parts go bad. This is because the previous owner ran very little coolant and mostly water through the system for a very long time. So, the coolant system [was] completely rusted.

The crossover, water pump, radiator were complete rusted. When I changed the radiator, it literally crumbled in my hands. Same with the crossover pipe.

All the 20 year-old hoses are "melded" to whatever they are attached to.

I'm sure all the low-income Honda guys no what I am talking about. Basically, a basket-case.

But, when it's running, it runs really well and gets great gas-mileage.

Thanks for the replies. Shoot me any idea you may have. I'm an amateur, so I can use the advise.

esm

 

Ya I was thinking that maybe the nipple was already breaking off and when you tried tied to get the hose off it just broke because it was hanging on by a thread.

 

Hello.

I bought another thermostat housing for $15.00 today.

I talked to some of the engineers at work.

One guy is a car genius. [he once quoted me the bore and stroke limits on my 1971 Ford 360 to 390 crank/piston conversion from memory]

Anyway. . .

I am going to take the nipple out of the used thermostat housing by cutting the metal around the nipple and popping it out.

Then I am going to replace the nipple on the intake. I'll use some JB Weld to keep it it place.

Since I have to replace the intake manifold, or remove the manifold to tap it and put in a new, threaded barb; this will be an easy, quick fix that hopefully will keep the car moving until warmer weather [and more money] arrives.

Thanks for the help.

esmzoso

 

Hello.

Here is the diagram of my barb/nipple swap:



The nipple on the Thermostat housing is the same as the Intake. The Thermostat Housing nipple may be a little longer; but that actually works to my advantage.

Here is the used Thermostat Housing I got for $15.00.



I'm going to cut through the aluminum on the Thermostat Housing to get the Housing to "relax" around the nipple. It should pop-out relatively easy after the aluminum releases. I may have to cut in from more than one direction. The key here is to cut into the aluminum slowly, as not to heat it up around the nipple. That means I can't cut it with my Dremmel. I'll have to use a hack-saw and cut it by hand.

Then, I'll clean the nipple and the nipple housing on the Intake. I'll put a thin layer of JB Weld on the nipple and slide it back into the Intake. Hopefully, I won't push any JB Weld into the Intake. It should be fine as long as I pay attention to what I am doing.

I'll also put a thin layer of JB Weld where the nipple meets the Intake; in case there is an area where it doesn't make a complete seal.

I'll let the JB Weld set-up for 2 days. Then I'll attach the hose and I'll see what happens.

This is a short-term repair. The correct way to repair the intake is to remove it and tap-in a new, threaded nipple; or replace the Intake.

I'm thinking - start-off as cheap, fast and easy as possible; then work my way from there.

I know I'd like to get a solution that doesn't include me removing the top-half of the motor at the onset of winter. Right now, it's about 40 degrees, the wind is howling and it's pouring down rain.

esmzoso

 

i think getting a used lower intake manifold would be easier then replacing one that has a fractured hose connector stuck in it

 

Yes, I was just gonna say, get a used IM. It'd be easier.

 

Hello.

It looks as if my 2nd diagram didn't make it. Sorry about that.

_______

It took 10 minutes to remove the old barb/nipple from the used thermostat housing. I made two cuts and it came right out.

Now I just have to take a screwdriver and pull out the rest of the nipple in the intake. I'll try to use a modified paintcan opener to do it. It shouldn't take much, judging by the condition of what came out with the hose.

I'm going to try to that on Wednesday. It supposed to be warmer.

I appreciate the help. Thanks for posting.

esmzoso

 

lol seriously bro, just get another one. You do not want that thing to come apart and you lose all ur coolant in a matter of seconds and then blow your head gasket.

 

How about cutting the fitting off flush. Drill and tap the hole to pipe thread and pick up a common pipe to barb fitting. Old chevys were famous for breaking off heater hose fittings. I've drilled and tapped a quite a few.

 

Hello.

I apologize for not replying to the thread. I pinched a nerve in my back.

I have also been trying to refinance my house. What a joke that whole process is turning out to be. I've had better experiences with used car salesmen.

____

The replacement barb worked very well.

I found the used thermostat housing on eBay for $15.00. I cut a triangular cut around the barb and it popped right out.

The barb that came out of the intake was so deteriorated that it came out in one piece. When I went to compare the two [the one out of the intake and the one from the thermostat housing] they were the same length. [minus some length on the intake barb from rust]

So I took the new barb and coated it with JB Weld. When I went to push it in, it was a little tight. As a result, the JB Weld formed an excellent bead around the outside of the barb. I had to use a small hammer to tap the barb into the intake. But it took very little effort to get it in place.

As I was getting prepared to do the intake barb, I broke another one. It was one of the smaller barbs that attached in front of the fuel injection unit. [I can't think of the name of the part right now because of these stupid pain pills for my back]

Anyway, it was the same size as the smaller barb on the used thermostat housing. So I repeated the process and replaced it the same way.

Both worked great!

As a side bonus, I think that the rusted barb from the intake was introducing air to my coolant system. I haven't had another hose blow since I did the repair. [time will tell]

You guys are correct. The proper way to do it was to replace the intake. I'm just glad it worked for now.

My Mother is driving the Accord. My Niece is driving my Mother's Taurus. And I have my Nieces 2001 Mazda Tribute. The Tribute is losing oil pressure as it warms up. I wish I could come up with an easy fix to that.

Again, I apologize for the lack of response to the thread.
And Thanks again for all the help. I really appreciate it.

esmzoso