I used barbarian force to pull the return line off and the nipple broke off. I am going to see if I can find a slim metal sleeve to melt into the plastic stem on either side and then use epoxy to join the broken joint. Then I will smear some more epoxy around the outer edge of the joint. I was thinking about maybe trying a brass threaded nipple but am going for the metal sleeve and epoxy attempt first. I did see the ACDelco pump comes with a reservoir, but if I can fix this for cheap, I can justify buying HPtuners lol. Very expensive mistake on my part... I should have sliced a line in the hose with a razor to remove it.

 

Yes, the power of a simple razor blade.
Did you contact those junkyard sellers on ebay and see if any include the reservoir?
If you are going to attempt to repair, keep in mind: repair without flow restriction, since you will burn the pump in no time! There's a post back in 2012 that shows a decent repair, using a threaded barb fitting and JB weld.
Thread/jb weld the barb in. In the meantime check ebay for a used pump with reservoir.

 

No dielectric grease on the wire ends before inserting into new terminals?

 

Oversized wire/connection without insulator. Best to seal with Liquid Electrical Tape, Waterproof Seal, All Indoor/Outdoor Uses.

 

I started to write a message to one of the sellers but then decided to run to the store to see what I could find to MacGyver it.

I found this plastic bushing that fits perfectly on the inner stretch of the nipple. My concern is restricting the flow, like you mention. I'm going to shave down the inside of the bushing with a drill bit to bring the inner diameter closer to the original ID of the nipple. I am debating whether I want to keep it there permanently or if I want to temporarily place it during the reconnection of the old nipple (to prevent epoxy from entering the inside).

My concern with the bushing is restricted fluid flow or increased pressure on the low pressure return side.

My concern without the bushing is the likelihood of the nipple breaking without the support of the bushing.


(I'll be cutting the shoulder off the bushing)

 

Hey Justin, I chose not to use dielectric grease on the wire ends. I personally don't use it for contacts, just for insulation. I am planning on using the paint on electrical tape Hummerz suggested to seal up the wires entering the terminals. I'm hoping it will work well.

 

Here's where I'm at with the inner sleeve idea. I used a drill and have the bushing as close to paper thin as it will get. Some areas actually rubbed through. I used a soldering iron to clean up the nylon debris and I think this might work without restricting flow enough to cause problems (no math here, just intuition).

 

 

I am ordering a new power steering pump (the ACDelco unit) with the reservoir. I figure this old pump squeaked anyways, so I might as well. I am also ordering a serviceable in-line power steering filter.

I order from RockAuto, usually, and am trying to get everything I need/want with this order.

I am thinking about ordering a new set of injectors (for the 3.7L) since the current ones are for the 3.5L.

Any insight on 3.5L vs 3.7L injectors? I do see they are different part numbers, which is what is encouraging my interest in swapping them. I also would like to rule out the injectors from my unusual idle and difficulty starting on first turn.

 

Back in 2012, I was getting a p0300(random misfire) I ordered new plugs, cops, fuel injectors, and fuel induction cleaner. I changed the plugs&coils. P0300 still came up, I went with the problem solver! BTW, I never installed the injectors, and never had to check for intake leaks! 9yrs later, still no code, yet I have new set of injectors, and a good used set of cops.