B6 Inlet manifold cooling water connection broken off

[StanTheMan]

So final preparation for rego check I noticed a water leak on the inlet manifold.

While trying to fix it with a new bit of hose I broke the nipple that connects the water hose off.


How do I repair that?

[StanTheMan]

[speed]

You're really not having a lot of luck

Think you need to pull it out and either replace or cut it off and tap in a thread and screw in a fitting.
I was hoping that it would at least be the barb on the top part of the manifold, so you could have at least gotten to it easier.

Maybe someone else has a better idea.

[StanTheMan]

Thank you speed.

Let's not dwell on bad luck. It's about the journey. It's all part of it.

[StanTheMan]

If I drilled a hole into it at the front, then run a hose from there to the idle valve?

[speed]

It's difficult for me to see which way is up in your pic.

Here's one from the net showing what it should look like.



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[StanTheMan]

The bit you see is at the bottom of the air intake manifold
Right at the top is the cam cover. Front of the engine is towards the right.
The 2 hose you see connect the idle bypass valve on the intake manifold
The bolt hole is the head. It's about where numbe 1 cylinder is located

The problem is at the bottom of the air intake manifold just to the right of no 1 cylinder injector and prolly 5cm below where the injector is located

The idle controll valve is fine. The hose connects the broken nipple with the idle controll valve.

[StanTheMan]

If I drilled a hole into it at the front, then run a hose from there to the idle valve?

Let me just clarify
Drill a hole on the flat surface.
Attach hose over new hole which I've drilled but it also covers the existing hole.
Secure hose with a screw on clamp
Then run hose to attach to the idle controll valve

[speed]

If I drilled a hole into it at the front, then run a hose from there to the idle valve?

Let me just clarify
Drill a hole on the flat surface.
Attach hose over new hole which I've drilled but it also covers the existing hole.
Secure hose with a screw on clamp
Then run hose to attach to the idle controll valve

Sorry Stan, I'm in the office today
So it's actually on the head?

If you can drill and tap the new hole that goes into the same gallery yet covers your old hole it should work.

Then fit a barb and connect your hose with a clamp like you mentioned.

If you use grease on the drill and tap you should heavily reduce the amount of metal shavings, that is if it's in the head.
Sorry I'm lost on the actual location but principle is the same.

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[Nevyn72]

If I drilled a hole into it at the front, then run a hose from there to the idle valve?

Let me just clarify
Drill a hole on the flat surface.
Attach hose over new hole which I've drilled but it also covers the existing hole.
Secure hose with a screw on clamp
Then run hose to attach to the idle controll valve

That is pretty much exactly what I was going to suggest.

Either that or cut off the flat end which gives you pretty much the same result.
I suppose it would depend on what is easier, drill or cut?

Either way you will need to clean up the sharp edges in the area where the old barb snapped off or it will just progressively cut through the new hose.....

[StanTheMan]

Cheers done & dusted.

Without taking the manifold off there is no way I can det to it with a file to smooth it out. I guess it's a project.
The hose is now attached & she's ready for rego

[Okibi]

Been there, bi-passed that.

[StanTheMan]

for the benefit of those who didn't understand where this located.

its on the intake manifold
not the head.

image attached

image002.jpg

[speed]

Yeah I didn't think it was on the head but knew it was L shaped.

It was the comment about the bolt hole is in the head that threw me but I later realised you were talking about what was above the broken L shape fitting.

My bad but the same principle applied.

When you do.get a chance to remove the inlet manifold you can fix it for good

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[jp928]

I have had the steel pipe coming off the water neck rust out and die. Got a 1/8 BSPP tap, 8mm drill, 1/8 BSP nipple (or tail to some- short thread, barb for 5/16 hose). Works fine, doesnt leak.

jp 92 NA6 96 NA8 turbo.