FZJ80 PHH Bypass Pesky Heater Hose w/ Pics

[JimmyMc]

I initially just replaced the small (pesky) piece of hose on the block, but it leaked. It is a real pain trying to get the new little hose on the block and pipe, and secure the hose clamps, in such a tight space. The second time around, I decided to go with the bypass, and it was way easier. This time I didn't bruise my arms!

I found that O'Reilly's carries Gates Green Stripe Heater Hose and Constant Tension Hose Clamps. Call in advance to make sure they have the Gates Green Stripe 5/8" inner diameter and the Constant Tension Clamps. The clamps were in the back, not on the shelves, and they ordered a box of Green Stripe just to cut me off a few feet. This is much cheaper than ordering a PHH "kit" online.

To remove the old heater pipe, the "wiggle until it breaks" method did not work for me. I had to bend it out of the way and use a 12mm open end wrench with a ratchet on one side to remove the bolt by the firewall. It was still a pain even with that handy little wrench.

With the old pipe out and the leaky hose removed, installing the bypass was cake.

I have been wheeling with it like this for a month and it hasn't leaked.

 

[gsdog2]

Now replace that smaller hose in front of the phh in pic #2. That one is a huge PITA to change. Fails for the same reasons as the phh.

 

[JimmyMc]

Now replace that smaller hose in front of the phh in pic #2. That one is a huge PITA to change. Fails for the same reasons as the phh.

Yeah I will have to do that. Didn't even notice that bugger until you mentioned it. Thanks!

 

[MoJ]

@JimmyMc
That bundle of wires without a sheath resting on the egr pipe is making me nervous.

 

[Mig]

I just changed the PHH the weekend before last. Couldn't get a wrench or socket down to the second mount bolt on the back. I did find that i could get enough flex in the pipe to get the hose on the pipe. That was the easy part. Once i had the hose on the pipe, there wasn't enough room for a straight shot on to the nipple on the side of the engine. Spent a couple hours trying to pull the hose over the nipple from the side. BTW if anyone is interested in a weight lifting g regimen we can talk. When i got tired of that exercise program and was really starting to cuss, my wife showed up and suggested using her pick set (actually her initial suggestion was a crochet hook) to help pull the mouth of the hose on the nipple by running it around the edge. Then she brought me her set of picks, i tried it, and it took all of 10 minutes.

Yes, the answer was obvious after it was thrown in front of me, but i was busy with my tunnel vision. And while its frustrating at times, I'm glad i have her around for the occasional dope slap. I suspect everyone needs them at times, but I KNOW I need them at times.

Hope the tip helps someone else.

Mig

 

[richardlillard1]

Spend less time freaking about your PHH and more time looking at that wiring harness next to your EGR

 

[Red Merle]

Spend less time freaking about your PHH and more time looking at that wiring harness next to your EGR

That looks ready for a full DefCon1 meltdown.

 

[landtank]

BTW, that's the wrong heater valve for your truck. That is for a 3FE if it is for an 80. The flow direction is backwards.

 

[JimmyMc]

@JimmyMc
That bundle of wires without a sheath resting on the egr pipe is making me nervous.

View attachment 1490351

Thanks MoJ! I noticed that when I was replacing the hose. They weren't quite touching but it was too close... It's been taken care of though.

 

[JimmyMc]

BTW, that's the wrong heater valve for your truck. That is for a 3FE if it is for an 80. The flow direction is backwards.

Thanks for catching that. I never would have thought to consider it might be backwards or the wrong part. The truck doesn't overheat and all the heat works. I will have to order the correct valve.

 

[Seansfj80]

Well my PHH finally gave out. Let the fun begin! I'm not going to do the bypass. I'm a glutton for punishment I suppose. Anyways found the replacement hose on Pesky Heater Hose Kits. I remember reading somewhere the blue was softer and better than the green stripe. Am I right. Which one is easier to install?

 

[ceylonfj40nut]

I would sleeve the phh bypass with a larger dia hose so that manifold contact does not chafe the bypass pipe. I did this on mine. I could not tell if you had a sacrificial hose.

 

[madisonr34]

Yeah I will have to do that. Didn't even notice that bugger until you mentioned it. Thanks!

If you bypass the throttle body, it's easy.

 

[mxjunkie80]

What do you lose if you do the bypass method?

 

[ceylonfj40nut]

A small portion of hard to reach metal pipe. Nothing else. Performs the same.

 

[Tonkaboy]

Thanks to mudder threads like this, I got some green stripe connected with 27mm spring hose clamp from Grainger. (Dealership on-screen search results turned up clamps better suited to thinner-walled hose.)

As my O'Reilly by-the-foot hose had a 'natural' curvature matching my intake bend radius, rolled along with this adding a lined cable clamp which is a bit large now, will resize tighter to hold up & away from the throttle cable sometime soon.