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Emergency Road Bypass
Couple bucks worth of 3/4" brass hose-barb fittings from Home Depot could get you going. Swap the plug and coupler if you don't need heat.

Last modified: Nov 19, 2008

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TonyJ's Pix | 9-5 Heater Bypass
Problem and Solutions

This album contains 11 photos and 0 albums.


Di-sected valve
failed at only 44k Miles- note ruptured small diaphram
Last modified: Oct 22, 2008

how it looked when whole
Last modified: Oct 22, 2008

Suddden big hole=rapid coolant loss
Last modified: Nov 19, 2008

Emergency Road Bypass
Couple bucks worth of 3/4" brass hose-barb fittings from Home Depot could get you going. Swap the plug and coupler if you don't need heat.
Last modified: Nov 19, 2008

How it works.
More info here than WIS. Haynes doesn't cover this valve at all in the cooling section, but it shows up in a picture about the boost bypass valve above it on the firewall.
Last modified: Nov 22, 2008

Alternative with o-ring seal that can't fail catastrophically
Top, L to R: Self bonding silicone tape (e.g. pegasus.com), RTV sealant, Valve..PLR-5945 <$20 SummitRacing.com; bottom: SCH 40 PVC pipe plug, SS clamp, Nylon 1/4-20, rubber washer, 1/2" wellnut
Last modified: Nov 19, 2008

The middle port must be blocked
Use RTV on the end and sides before inserting the rubber wellnut, but be careful not to let a glob get loose -- not good for cooling system. Check by pushing the valve open so you can see from the opposite port.
Last modified: Nov 19, 2008

Outer plug -to make sure
Drill PVC plug 11/16"; careful not to make hole in the end! Cut 6 slots ~halfway, using a band or hack saw. Either inner or outer alone might work, or use a 5/8" brass plug, hose, + 2 clamps. Use~7" of silicone tape to enlarge small port
Last modified: Nov 19, 2008

How to connect it.
The output ports are ~1.5" farther apart, but there is lots of flex in the hoses. I haven't actually installed it yet- will need to mount (tie wrap?) the device that clips into the slot behind the valve
Last modified: Nov 19, 2008

Poll Results
58% of 69 poll responders replaced it (50.7% because it failed) after an average of 76K miles (min 20K, max 195K, median 75K); no strong correlation with model year (only one 2005 response)
Last modified: Dec 24, 2008

Cumulativ prob of bypass replacement
By 40Kmiles, there is a 10% probability of replacement due to actual or feared failure; by 80Kmi; it's up to 35%, etc.
Last modified: Dec 24, 2008


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