PI Swap - Heater Hose Nipple Problem
I mentioned this in another thread, but the situation just go worse, so I'm needing some help.
The guides I've read indicate that removing the old heater hose nipple is a simple matter of tapping out the old one and tapping in the new one. This is what has happened for me:
Removing the old nipple was a major task. Tapping it out didn't work. I eventually soaked it multiple times with WD40 and had to heat it up before I could tap it loose. By then, the front was mangled and I had to cut it in half and slide it out in two pieces.
Pictures show that the end of the old nipple that isn't poking through should have a flange on it. When mine came out, it... kinda didn't. What it had was a folded down lip that looked like it used to have a flange but that the flange was folded down around the outside of the nipple. But this was only on 3/4 of the flange area... the last 1/4 looked like the opposite... as though the flange had been pulled out away from the exposed end.
So what? 3/4 of the flange got folded back over the nipple as I slid it out but 1/4 got pulled away from me? That doesn't make any sense.
But whatever... it's out, right?
Well, the new nipple won't slide in. The PI nipple has the flange, the surface that actually sits in the block, and then the O-ring part is actually smaller around. The part with the O-rings can slide through that bore in the block, but when it comes to actually sliding in the mating surface, it won't go. I tried a hammer, and it still won't. I stuck some sockets in there to see what size it is... I can't get anything bigger around than 0.655" in that bore, and the nipple diameter on the mating surface is 0.740". No wonder it wouldn't slide in.
When I look through where the water pump used to be, it looks like that bore actually has some sort of sleeve in it. I see what looks to be the casting and then another ring inside it that looks like maybe a pressed-in insert. Now, I thought that sleeve was supposed to be there since it provides a nice surface for the nipple to seal against, but now I have no idea. The nipple I ordered was F75Z-8555-AA.
Ok... so I'm at a loss. I can take the nipple to work and to shave the extra off on a lathe, but that really doesn't seem like the right solution. Any ideas?
Edit: Forgot to mention, there was what looked like a thin bead of metal (or loctite?) left in the bore after I pulled out the old nipple. I was just going to gently grind it off since it was right where the nipple exited the block.