How do you replace the Heater Water Bypass elbow?

guitarfish · 01-30-2007, 09:32 PM

I have a 97 GP 3800 and coolant is leaking out the plastic elbow. I'm looking for a step by step, I've never done this one before.

Also, besides a new elbow, are there any other parts (e.g. gaskets, o-rings) that I will need?

BNaylor · 01-31-2007, 01:58 AM

We have a procedure to remove the tensioner assembly at Tips & Maintenance. You can get the elbow from the dealer or aftermarket, Motormite brand. There are two o-ring seals. See link below.

Click here

guitarfish · 01-31-2007, 08:17 AM

Excellent! Thank you, this is exactly what I was looking for.
One additional question - when installing the new elbow, do you recommend using any gasket sealant?

BNaylor · 01-31-2007, 09:17 AM

I never did but I suppose it wouldn't hurt to use hi-temp RTV silicone sealant. Good luck and let us know how it turns out.

richtazz · 01-31-2007, 12:20 PM

RTV may react with the rubber o-ring, so don't use it as it could cause more harm than good. Rub a little coolant on the o-ring to lubricate it when putting it in to ease installation.

wlkjr · 01-31-2007, 07:19 PM

Quote:

Originally Posted by richtazz

RTV may react with the rubber o-ring, so don't use it as it could cause more harm than good. Rub a little coolant on the o-ring to lubricate it when putting it in to ease installation.

Or some Astroglide. Has many good purposes.

BNaylor · 02-01-2007, 08:53 AM

Quote:

Originally Posted by wlkjr

Or some Astroglide. Has many good purposes.

Astroglide?

Isn't that stuff personal lubricant? I heard females may use it for their play toys.

wlkjr · 02-01-2007, 06:18 PM

Quote:

Originally Posted by bnaylor

Astroglide?

Isn't that stuff personal lubricant? I heard females may use it for their play toys.

Well, yeah it is a personal lubricant, but it is waterbased and can be used for other things too. As Jeff Foxworthy said, "with this stuff you can park a Cadillac in a doghouse."

guitarfish · 02-01-2007, 06:28 PM

O-kaayyyyyyy well getting back on topic, my son replaced the elbow today. Left the heater hoses attached, he lost maybe a quart of coolant doing the whole job, if that.

He's a novice, it took him about 2 hours taking his time. Not too bad. Hopefully the leaks are gone now. It's been edjumactional.

robertjtucker · 05-12-2007, 02:36 PM

I have gone through the removal instructions and done all these things, (except remove the 2 hoses). I am to the point I am ready to remove the tensioner but it won't come loose from the point where the coolant goes into the water pump. I can get it to rock up and down but it just won't come loose. Is there some thing holding it together like a o-ring or something. I didn't want to pry to hard because I didn't want to break anything.
Thanks,
Bob

guitarfish · 05-12-2007, 03:34 PM

Hi Bob,

I pulled up a picture of my tensioner from when I did the job, there appears to be 3 bolts, one below the heater hoses, the other two near the tensioner pulley. Did you remove these three?

When I removed mine the first time, the elbow was disintegrated at both the manifold and the tensioner, so it practically fell out. I had to disassemble it a couple weeks later however, and this time it was tighter because the elbow was intact. There's an o-ring on each end of the elbow which makes a tight seal.

I seem to remember getting a tire iron and gently applying pressure to pry the tensioner away from the manifold. It was that tight. Rotate the tensioner up and down as you apply pressure, it should come out.

Let me know how you make out.

guitarfish · 05-12-2007, 03:36 PM

Something additional - the tensioner assembly itself has a connection into the engine with an o-ring of its own. It's actually this connection that required the tire iron. It may be what's holding you up.

robertjtucker · 05-13-2007, 10:38 AM

Yeah my elbow disinegrated also. I have all the bolts removed, and all that it is being held in by is the connection I thought to be where the tensioner goes into the water pump. I can lift up and down but it isn't coming out. I tried prying on it with a large screw driver and it hasn't budged but I was afraid of damaging something so I wasn't putting to much weight into it.

So if it is an O-ring I feel a little better about not breaking anything. So you just used a pry bar and wiggled as you pryed? Did you replace the o-ring after wards or can it be reused?

This would have been a pretty easy job if not for this part. I have been going back and forth with it for a couple weeks now.

Thanks for the assist,
Bob

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