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I snapped the coolant reservoir connector for the return side when I was in the middle of removing the ignition coils to change the spark plugs. I went to my local dealer and they don't sell the connectors and required purchasing an entire coolant hose for $50. No thanks.
I went online and saw these things sell for $8 shipped on pelicanparts. While I'm waiting for the proper replacement to arrive, I have the itch to continue driving my car, not wanting to miss a day with it, so I decided to repair the connector.
All the parts required is a 5/16" barb x 1/8 MIP fitting.
I first sanded down the broken neck with a rotary tool.
Then I drilled a hole using 11/32" bit and tapped it with a 1/8" NPT 27. I drilled roughly 1/4" deep. As you can see, with 1/4", theres still plenty of material left surrounding where the metal clip goes.
I fastened the barb fitting with some thread sealer and waited 24hr for curing. And it's complete!
Here it is installed.
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